Factory Workshop Manual
Make
Dodge
Model
Grand Caravan
Engine and year
V6-181 3.0L SOHC (1989)
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This manual was submitted by
Anonymous
Date
1st January 2018
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations
Electronic Brake Control Module: Locations
The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine
compartment. The CAB uses the wheel speed information from the wheel speed sensors to control
the ABS system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 7
Electronic Brake Control Module: Description and Operation
The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine
compartment. The CAB uses the wheel speed information from the wheel speed sensors to control
the ABS system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 8
Electronic Brake Control Module: Service and Repair
1. Turn ignition Off. 2. Remove speed control servo. 3. Disconnect wiring harness 60-way
connector from anti-lock brake controller. 4. Remove controller mounting bolts, then the controller.
5. Reverse procedure to install. 6. Torque controller attaching bolts to 40 in. lbs. and electrical
connector screw to 105 in. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Locations
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module >
Component Information > Locations
Lower Instrument Panel Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module >
Component Information > Locations > Page 17
Cruise Control Module: Testing and Inspection
Fig. 5 Engine Controller 60-Way Connector, Shown From Terminal End
1. Set voltmeter to read 12 volts, then connect negative lead to chassis ground. 2. Connect positive
lead to pin 7 of module connector then drive vehicle at speeds between 40 - 50 mph. 3. Turn speed
control switch to the On position. Voltmeter should read 12 volts. 4. Press and release the speed
control Set button. The voltmeter should indicate from 5 - 9 volts and fluctuate 1 - 2 volts at a rapid
rate. 5. Speed control system should be performing throttle control at this time, maintaining set
speed. If not, replace control module.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > A/C Compressor Clutch Cut-Out Relay
Compressor Clutch Relay: Locations A/C Compressor Clutch Cut-Out Relay
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > A/C Compressor Clutch Cut-Out Relay > Page 23
Compressor Clutch Relay: Locations A/C Wide Open Throttle Cut-Out Relay
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 24
Compressor Clutch Relay: Description and Operation
The A/C clutch relay is connected to the A/C damped pressure switch and the A/C switch. This
relay is in the On position during normal engine operation, but is closed when the SMEC senses
low idle speeds or wide open throttle conditions, preventing A/C clutch engagement.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC >
Component Information > Locations
Condenser Fan Motor Relay: Locations
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Locations
Audible Warning Device Control Module: Locations
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Low Fuel Indicator Relay >
Component Information > Locations
Low Fuel Indicator Relay: Locations
Low Fuel Relay
The low fuel relay is located on the back of the instrument cluster, behind the message center.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Malfunction Indicator Lamp
Driver Module > Component Information > Locations
Malfunction Indicator Lamp Driver Module: Locations
Upper I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > 4 Speed A/T
Backup Lamp Relay: Locations 4 Speed A/T
Engine Compartment.
The Backup Lamp Relay is located in the right rear corner of the engine compartment, on the side
shield.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 47
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 48
Interior Lighting Module: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 49
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Relay: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 54
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 55
Interior Lighting Relay: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 56
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Lighting Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 61
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 62
Trailer Lighting Module: Electrical Diagrams
Rear Lighting & Trailer Tow Wiring Circuit SH-68 - Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 63
Rear Lighting & Trailer Tow Wiring Circuit SH-79 - Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Body Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 70
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13
Engine Control Module: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 >
Page 79
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds
Engine Control Module: Customer Interest ECM - Engine Die Out at Low Speeds
NO.: 18-11-91
GROUP: DRIVEABILITY
DATE: Aug. 26, 1991
SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L &
3.3L Engines
MODELS:
1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON
(AQ) CHRYSLER'S TC
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH >> ARROWS <<.
SYMPTOM/CONDITION:
Vehicle may exhibit either or both of the following conditions:
Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine
dies out when throttle is closed.
Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM
but fail to continue idling. Engine will run normally if throttle is held open.
These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on
for extended periods of time and only when the ambient temperature is above 40~ F (4~ C).
DIAGNOSIS:
Connect a DRB II tester to the vehicle diagnostic connector.
1. With the engine at normal operating temperature and with the AC on, record the AIS position
while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open
throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the
throttle open less than the AIS position at idle in DRIVE?
2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes
to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open
throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the
AIS position at idle in DRIVE?
3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following
repair procedure.
PARTS REQUIRED:
1 Single Module Engine Controller (SMEC)
1989 3.0L Engine AS Body, Federal
4639386
AS Body, California 4639001
AC Body, Federal 4639382
AC Body, California 4639384
1990 3.0L Engine
>> AS Body, Federal (except Town & Country) 4639422 <<
>> AS Body, California (except Town & Country) 4639424 <<
AC & AY Bodies, Federal 4639398
AC & AY Bodies, California 4639400
AQ Body, Federal 4650386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 84
AQ Body, California 4650388
>> AS Body, Federal (except Town & Country) 4639386 <<
>> AS Body, California (except Town & Country) 4639001 <<
1990 3.3L Engine AS Body, Federal
4672435
AS Body, California 4672438
AC & AY Bodies, Federal 4672440
AC & AY Bodies, California 4672431
1 Authorized Modification Label 4275086
REPAIR PROCEDURE:
This repair involves the replacement of the engine controller with a revised one.
1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS
REQUIRED.
Figure 1
2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1,
and attached near the VECI label.
* INSERT PART NUMBER USED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC
13
Engine Control Module: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC
13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC
13 > Page 90
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds
Engine Control Module: All Technical Service Bulletins ECM - Engine Die Out at Low Speeds
NO.: 18-11-91
GROUP: DRIVEABILITY
DATE: Aug. 26, 1991
SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L &
3.3L Engines
MODELS:
1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON
(AQ) CHRYSLER'S TC
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH >> ARROWS <<.
SYMPTOM/CONDITION:
Vehicle may exhibit either or both of the following conditions:
Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine
dies out when throttle is closed.
Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM
but fail to continue idling. Engine will run normally if throttle is held open.
These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on
for extended periods of time and only when the ambient temperature is above 40~ F (4~ C).
DIAGNOSIS:
Connect a DRB II tester to the vehicle diagnostic connector.
1. With the engine at normal operating temperature and with the AC on, record the AIS position
while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open
throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the
throttle open less than the AIS position at idle in DRIVE?
2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes
to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open
throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the
AIS position at idle in DRIVE?
3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following
repair procedure.
PARTS REQUIRED:
1 Single Module Engine Controller (SMEC)
1989 3.0L Engine AS Body, Federal
4639386
AS Body, California 4639001
AC Body, Federal 4639382
AC Body, California 4639384
1990 3.0L Engine
>> AS Body, Federal (except Town & Country) 4639422 <<
>> AS Body, California (except Town & Country) 4639424 <<
AC & AY Bodies, Federal 4639398
AC & AY Bodies, California 4639400
AQ Body, Federal 4650386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds >
Page 95
AQ Body, California 4650388
>> AS Body, Federal (except Town & Country) 4639386 <<
>> AS Body, California (except Town & Country) 4639001 <<
1990 3.3L Engine AS Body, Federal
4672435
AS Body, California 4672438
AC & AY Bodies, Federal 4672440
AC & AY Bodies, California 4672431
1 Authorized Modification Label 4275086
REPAIR PROCEDURE:
This repair involves the replacement of the engine controller with a revised one.
1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS
REQUIRED.
Figure 1
2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1,
and attached near the VECI label.
* INSERT PART NUMBER USED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations
Engine Control Module: Component Locations
Single Module Engine Controller
The Single Module Engine Controller is located on the front left hand side of the engine
compartment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations >
Page 98
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions
Engine Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 101
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 102
Engine Control Module: Connector Views
14-Way Connector (1989 3.0)
Single Module Engine Controller Connector(14-Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 103
Single Module Engine Controller Connector(60-Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 104
60 Way (SMEC) Wiring Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 105
Engine Control Module: Description and Operation
Fig. 2 Single Module Engine Controller (SMEC)
The SMEC, Fig. 2, is mounted in the engine compartment and contains circuits necessary to
energize the ignition coil, fuel injectors and alternator field in order to minimize electrical noise in
the passenger compartment. The SMEC contains a voltage converter which converts battery
voltage into a regulated 8 volt output to energize the ignition pick up coil. The externally mounted
Automatic Shut Down (ASD) relay which interrupts power to the fuel pump, ignition coil and injector
when necessary is controlled by the SMEC. The ASD relay is turned on and off by the SMEC in
response to distributor reference pulses. When distributor reference pulses are transmitted to the
SMEC, the SMEC activates the ASD relay. However, when no reference pulse is transmitted to the
SMEC, the ASD relay is deactivated and power is shut off to the fuel control system and ignition
coil. The SMEC has been programmed to monitor several different circuits of the fuel injection
system in order to provide a self-diagnosis function. In conjunction with the self-diagnosis function,
a check engine lamp is wired into the system to indicate a failure in the monitored circuits. The
check engine lamp is illuminated for 3 seconds whenever the engine is started as a `bulb test.'
However, if the SMEC detects a malfunction in one of the monitored circuits the check engine lamp
will be illuminated and will remain on as long as the ignition key remains in the on position.
Illumination of the check engine lamp indicates that the system has entered the `limp-in' mode and
signals an immediate need for system service. If vehicle performance or the check engine lamp
indicate fuel injection system malfunctions, certain procedures should be followed. Prior to
suspecting the fuel injection service as the cause for complaints, ensure that the engine and all
related systems are in proper operating condition. After checking related systems, inspect fuel
injection components and connecting harnesses as outlined in Visual Inspection, repair system as
indicated, then road test vehicle to check system operation. If service performed during visual
inspection does not correct observed malfunctions, or if check engine lamp remains illuminated,
refer to `Obtaining fault codes' to call up fault codes stored in the SMEC memory and correct as
needed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 106
Engine Control Module: Service and Repair
1. Remove air cleaner duct from SMEC.
2. Remove battery.
3. Remove two SMEC mounting screws.
4. Remove SMEC electrical connectors.
5. Remove SMEC.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Component Locations
Main Relay (Computer/Fuel System): Component Locations
Relay Locations--next To Battery
The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the
inner fender.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Component Locations > Page 111
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram
Information and Instructions
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram
Information and Instructions > Page 114
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 115
Main Relay (Computer/Fuel System): Description and Operation
Relay Locations--next To Battery
The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel
pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel
injectors, and electric fuel pump at all times when the ignition switch is in the START position.
When the ignition switch is in the RUN position and the engine control module is receiving
reference signals from the distributor, power will also be supplied. If there is no reference signal
after two seconds the engine control module will de-energize the ASD and no power will be
supplied to the ignition coil, fuel injectors, or electric fuel pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection
> Auto Shutdown (ASD) Relay
Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay
Relay Terminal Identification
ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with
circuit codes, and color codes, and their function:
Circuit No. Terminal No. Color Code Description
J1 30 Red Has battery input voltage supplied through fusible link.
Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output
voltage to fuel pump, O2 sensor, fuel injectors, and coil.
K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine
Controller (SMEC). The SMEC provides input voltage to relay.
K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when
distributor signal is present.
N/A 87A N/A Not used in these applications.
ASD RELAY TEST
NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent.
Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no
scanner is available proceed with the following test.
1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage.
If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present
proceed to step 2.
2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to
the START position and crank the engine. If
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection
> Auto Shutdown (ASD) Relay > Page 118
output voltage is present during cranking, the ASD relay is functioning normally and no further
testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3.
3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key
to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is
present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC
connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86)
wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If
continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for
SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD
relay, and test operation.
4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START
position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and
drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning,
and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If
no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14
(terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists
replace and ASD relay and test operation.
5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter
between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58
of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and
ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE
CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Polarity Protection Relay, ECM > Component Information > Locations
Polarity Protection Relay: Locations
Relay Identification
The ASD relay is found on the left inner fender apron near the left strut tower and the diagnostic
connector.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Engine Compartment Components
This vehicle utilizes the Automatic Shutdown (ASD) Relay to control the Fuel Pump operation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component
Locations
Main Relay (Computer/Fuel System): Component Locations
Relay Locations--next To Battery
The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the
inner fender.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component
Locations > Page 130
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram
Information and Instructions
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram
Information and Instructions > Page 133
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 134
Main Relay (Computer/Fuel System): Description and Operation
Relay Locations--next To Battery
The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel
pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel
injectors, and electric fuel pump at all times when the ignition switch is in the START position.
When the ignition switch is in the RUN position and the engine control module is receiving
reference signals from the distributor, power will also be supplied. If there is no reference signal
after two seconds the engine control module will de-energize the ASD and no power will be
supplied to the ignition coil, fuel injectors, or electric fuel pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection >
Auto Shutdown (ASD) Relay
Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay
Relay Terminal Identification
ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with
circuit codes, and color codes, and their function:
Circuit No. Terminal No. Color Code Description
J1 30 Red Has battery input voltage supplied through fusible link.
Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output
voltage to fuel pump, O2 sensor, fuel injectors, and coil.
K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine
Controller (SMEC). The SMEC provides input voltage to relay.
K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when
distributor signal is present.
N/A 87A N/A Not used in these applications.
ASD RELAY TEST
NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent.
Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no
scanner is available proceed with the following test.
1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage.
If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present
proceed to step 2.
2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to
the START position and crank the engine. If
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection >
Auto Shutdown (ASD) Relay > Page 137
output voltage is present during cranking, the ASD relay is functioning normally and no further
testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3.
3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key
to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is
present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC
connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86)
wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If
continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for
SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD
relay, and test operation.
4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START
position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and
drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning,
and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If
no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14
(terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists
replace and ASD relay and test operation.
5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter
between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58
of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and
ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE
CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions
Ignition Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 143
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Fig. 45 Airbag system diagnostic module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Engine Compartment & Front End Components.
On Left Fenderwell
Applicable to: 4-153/2.5L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 152
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 153
Engine Compartment & Transaxle Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495
> Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495
> Jun > 95 > A/T - Poor Shift Quality > Page 164
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
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1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
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Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
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> Jun > 95 > A/T - Poor Shift Quality > Page 167
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
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13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
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> Jun > 95 > A/T - Poor Shift Quality > Page 169
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
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211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
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211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 174
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692
> Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
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> Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 179
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290
> Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting
Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
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3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
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Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
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Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 190
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 191
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 192
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
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Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 193
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
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Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 194
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
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Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 195
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
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Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 200
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 205
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
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Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting
Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
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Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 210
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
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Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
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Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 215
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 216
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 217
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 223
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 224
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 225
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 228
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 229
Control Module: Diagrams
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 230
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 231
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 232
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 233
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 234
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 235
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 236
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 237
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 238
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 239
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604
Control Module: Description and Operation A604
DESCRIPTION
This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped
similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code
memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 242
Control Module: Description and Operation 41TE
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 243
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 -
Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 246
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 250
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 251
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 252
Transmission Control System Relay: Description and Operation
DESCRIPTION
This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to
the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay,
voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in
this mode, only second gear, reverse and neutral are available.
This relay may also be referred to as the Safety Shutdown Relay.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations
Transmission Position Relay: Component Locations
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page
257
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations
Wiper Control Module: Locations
I/P, Cowl & Steering Column Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Locations
Power Door Lock Switch: Locations
Front Door Components
In Front Door Armrest
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection > Sliding Door Circuit Test
Power Door Lock Switch: Testing and Inspection Sliding Door Circuit Test
Sliding Side Door Power Lock Assembly
1. Connect one lead of a test light to the upper contact of the pillar, and place the other lead to the
lower contact.
2. If the test light illuminates when the lock switch is depressed, the wiring circuit to the contacts is
good. If the test light does not illuminate, check the electrical connectors at the right side cowl,
check for a broken wire, or see Circuit Breaker Test.
3. With the sliding door partially open, connect jumper wires across contacts on pillar to contacts on
the door. The door should lock or unlock when
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 269
these jumper wires are connected and the switch is depressed.
4. If the door locks and unlocks, the problem is in the door and pillar contacts (check for proper
shim at the door contact plate). If lock and unlock does not occur, remove trim panel and check for
voltage at the lock motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 270
Power Door Lock Switch: Testing and Inspection Switch Voltage Test
NOTE: The following test determines whether voltage is continuous through the wiring harness to
the power door lock switch.
1. Remove the door lock switch from the door trim panel.
2. Separate the multiple terminal block on the wiring harness from the door lock switch.
3. Connect one lead of a test light to the black wire terminal and the other lead to the red wire
terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning
properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check
for an open in the wiring harness.
4. If the wiring circuit is functioning properly, See: Body and Frame/Locks/Power Locks/Power Door
Lock Actuator/Testing and Inspection
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 271
Power Door Lock Switch: Testing and Inspection Door Lock Switch Test
Door Lock Switch Continuity
Remove each door lock switch from the door trim panel. Connect an ohmmeter to the switch and
check that there is continuity in lock and unlock positions (refer to the image shown). If these
results are not obtained, replace the switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection > Page 272
Power Door Lock Switch: Service and Repair
1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect
wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Power Mirror Switch: Locations
Front Door Components
In Center Of Door Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations
Power Seat Switch: Locations
Power Seat Components
Outboard Side Of Seat
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate
Lock Switch > Component Information > Locations
Power Trunk / Liftgate Lock Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations
Seat Heater Switch: Locations
Lower I/P Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
Front Body Components
Front Center Of Headliner
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations
Trunk / Liftgate Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
Engine Compartment Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Locations > Page 295
Engine Compartment & Transaxle Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Locations > Page 296
Brake Fluid Pressure Sensor/Switch: Description and Operation
The switch activates a light on the dash panel to indicate that one of the hydraulic systems has
failed. There are two basic types of switches. In some earlier models, as pressure falls in one
system, the normal pressure of the other system forces the piston to the inoperative side where it
contacts the switch terminal, causing the warning lights to illuminate.
On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one
side of the system, the piston in the valve is forced toward the failed side where it latches in
position and illuminates the warning light.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
I/P, Cowl & Steering Column Components
LH Kickpanel On Park Brake Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
The wheel speed sensors are located at each wheel and transmit wheel speed information to the
Controller Anti-Lock Brake.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Page 303
Wheel Speed Sensor: Description and Operation
The wheel speed sensors are located at each wheel and transmit wheel speed information to the
Controller Anti-Lock Brake (CAB).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Front
Wheel Speed Sensor: Service and Repair Front
Fig. 66 Front Speed Sensor Assembly
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove screw from clip
that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect
electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove
sensor head screw, then the sensor head from steering knuckle.
CAUTION: If sensor head is seized, use a punch and gently rock sensor back and forth until free.
Do not use pliers on sensor head.
5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and
Torque mounting bolt to 60 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 306
Wheel Speed Sensor: Service and Repair Rear
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring
grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical
connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts,
then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head
from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and
forth until free. Do not use pliers on sensor head.
6. Reverse procedure to install. Torque sensor mounting bolt to 60 inch lbs. and U-bolt nuts to 65
ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Component Locations
Coolant Temperature Sensor/Switch (For Computer): Component Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Component Locations > Page 314
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 315
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 5 Coolant & charge temperature sensors
The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the
SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The
sensor provides a variable resistance which is proportional to coolant temperature. When the
engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and
increases engine idle speed to provide acceptable cold engine performance and allow quick warm
up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel
mixtures and lowers engine idle speed to provide proper exhaust emission control and increased
fuel economy.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations
Temperature Sensor (Gauge): Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions
Temperature Sensor (Gauge): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 321
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 322
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 323
Temperature Sensor (Gauge): Testing and Inspection
When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the
gauge, check for a defective sending unit or wiring as follows:
1. Ground sending unit connector leads, at the sending unit, in the vehicle.
2. With ignition in On position, a grounded input will cause the fuel or temperature gauge to read
maximum or above.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Testing and Inspection
Brake Switch (Cruise Control): Testing and Inspection
1. Disconnect six cavity connector from stop lamp switch pigtail. 2. Using an ohmmeter, check
continuity at switch side of connector. 3. With brake pedal released, there should be continuity
between the dark blue/red and yellow/red wires, and between white/pink and white wires.
There should be no continuity between pink and white wires.
4. With brake pedal depressed, there should be continuity between pink and white wires. There
should be no continuity between the dark blue/red
and yellow/red wires, or between white/pink and white wires.
5. If the above results are not obtained the stop lamp switch is defective or out of adjustment.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise
Control > Component Information > Locations
Clutch Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Clutch Pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations
Cruise Control Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Brake pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations > Page 334
Cruise Control Switch: Testing and Inspection
Fig. 6 Speed Control Continuity Chart. 1988-90 Rear Wheel Drive Models
Fig. 7 Speed Control Continuity Chart. 1988-90 Front Wheel Drive Models
Fig. 8 Speed Control Connector Terminal Identification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations > Page 335
Fig. 9 Speed Control Continuity Chart. 1991 Models
1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a
continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. 3.
Results should be obtained according to the charts. If these results are not obtained, replace
switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations > Page 336
Cruise Control Switch: Service and Repair
1. Disconnect battery ground cable. 2. Remove lower steering column cover. 3. Remove four
plastic retaining clips from underside of steering column, then the trough. 4. Disconnect speed
control switch electrical connector from instrument panel harness connector. 5. Remove wiper
control knob from end of turn signal lever, then the silencer from lever. 6. Remove two screws
attaching speed control switch to column. 7. On tilt columns, remove steering wheel, then attach a
flexible guide wire to lower end of speed control switch harness. 8. Remove switch and harness
from column by gently pulling wires through lock housing between lock plate and side of housing.
9. On standard columns, remove attaching screws and the upper steering lock housing cover, then
pull harness up through column.
10. On tilt columns, insert harness connector through turn signal lever opening in column, then pull
upward through upper housing.
11. Attach guide wire to switch wiring harness, then gently pull downward through column opening,
between lock plate and side of housing.
12. On standard columns, insert harness and connector through turn signal lever opening in
column, then pull down and out lower end.
13. On all models, remove slack from all wires.
14. On tilt column, remove guide wires.
15. On all models, install wiring trough with plastic clips.
16. Connect speed control switch electrical connector to instrument panel harness connector.
17. Secure speed control switch to column with two screws.
18. Position silencer on lever, then push wiper control knob in place on end of lever.
19.
On tilt columns, replace steering wheel.
20. On standard columns, install upper steering column lock housing cover.
21. On all models, install lower steering column cover.
22. Connect battery ground cable, then test operation of speed control.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss
of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss
of Cruise Control > Page 345
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle
Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle
Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 351
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
Lower LH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions
Oil Pressure Sender: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 358
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 359
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Locations
Air Conditioning Switch: Locations
Lower I/P Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Front End Components
Behind Center Of Grill
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
High Pressure Sensor / Switch: Locations
Engine Components.
A/C High Pressure Switch located at rear Of A/C Clutch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations
Low Pressure Sensor / Switch: Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Dome Lamp Switch
Door Switch: Locations Dome Lamp Switch
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Component Information > Locations > Dome Lamp Switch > Page 379
Door Switch: Locations Door Ajar Switches
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Locations
Fuel Gauge Sender: Locations
Top Of Fuel Tank
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Locations > Page 383
Fuel Gauge Sender: Testing and Inspection
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit.
1. Disconnect wiring from fuel tank sending unit. 2. Connect wiring to a known good sending unit. 3.
Connect a jumper wire between sending unit pick up tube and ground.
Fuel Tank Sending Unit (Typical)
4. Check fuel gauge as follows: Allow at least two minutes for gauge to settle at each test point.
a. Move and clip float arm to its empty stop and turn ignition to the On position, gauge should read
Empty or below. b. Move and clip float arm to the Full position, gauge should read Full or above.
5. If gauge does not meet specifications, check the following items for possible malfunction:
a. Wiring and connections between gauge sending unit and multiple connector behind left kick
panel. b. Wiring and connections between multiple connector and printed circuit board terminals. c.
Circuit continuity between printed circuit board terminals and gauge terminals. If the above items
are satisfactory, the gauge is defective
and must be replaced.
6. If fuel gauge meets specifications check original fuel tank sending unit as follows:
a. Remove fuel tank sending unit from fuel tank and connect a jumper wire between sending unit
pick up tube and ground.
7. Repeat step 4. 8. If fuel gauge is now within specifications, check the following as possible
cause:
a. Ground wire from sending unit to left side cowl for continuity. b. Sending unit deformed. Ensure
float arm moves freely and pick up tube is not bent. c. Inspect float. d. Sending unit improperly
installed. Install correctly. e. Mounting flange on fuel tank for sending unit deformed. f.
Fuel tank bottom deformed causing improper positioning of pick-up tube.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
I/P, Cowl & Steering Column Components
LH Kickpanel On Park Brake Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > 3 Speed A/T
Backup Lamp Switch: Locations 3 Speed A/T
Neutral/Park Safety Switch
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions
Backup Lamp Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 394
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 395
Backup Lamp Switch: Electrical Diagrams
3 Speed A/T
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
4 Speed A/T
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 396
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 397
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Description and Operation > 3 Speed A/T
Backup Lamp Switch: Description and Operation 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
- It provides ground for the starter solenoid circuit through the selector lever in only Park and
Neutral positions.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Testing and Inspection > 3 Speed A/T
Backup Lamp Switch: Testing and Inspection 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Service and Repair > 3 Speed A/T
Backup Lamp Switch: Service and Repair 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Brake pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions
Brake Light Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 409
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 410
Speed Control & Stop Lamp Switch Wiring Circuit SH-25
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Page 411
Brake Light Switch: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then
remove switch assembly. 3. Install new switch and connect switch electrical connector. If
adjustment of switch is required, proceed as follows:
a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull back on
brake pedal until it will go back no further. This will cause switch to ratchet backward into correct
position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch >
Component Information > Locations
Dome Lamp Switch: Locations
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Dome Lamp Switch
Door Switch: Locations Dome Lamp Switch
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Dome Lamp Switch > Page 419
Door Switch: Locations Door Ajar Switches
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Service and Repair
Hazard Warning Switch: Service and Repair
1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering
wheel.
Steering column cover, silencer & reinforcement removal
3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot
in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever
electrical connectors. 6. On models equipped with standard column, proceed as follows:
a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove
washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to
washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then
remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws.
7. On models equipped with tilt column, proceed as follows:
a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove
ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control
lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control
lever shaft to full clockwise position, then remove shaft from washer/wiper switch.
Lock plate removal. Models w/tilt column
e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring
out of groove with a suitable screwdriver.
The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will
turn too easily and make removal difficult.
f. Remove lock plate, cancelling cam and upper bearing spring.
g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard
switch attaching screws, Place shift bowl in Low position.
Turn signal switch replacement
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Service and Repair > Page 423
8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up
from column while straightening and guiding wires
up through column opening.
9. Reverse procedure to install. Rearm airbag system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations
Headlamp Dimmer Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Diagram Information and Instructions
Headlamp Dimmer Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 429
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 430
Headlamp Dimmer Switch: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 431
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 432
Headlamp Dimmer Switch: Service and Repair
Dimmer switch replacement
1. Disconnect battery ground cable. 2. Remove left lower instrument panel cover, then tape dimmer
switch rod to steering column to prevent rod from falling out of notch in actuator
lever.
3. Remove switch to column attaching screws. 4. Disconnect switch electrical connector, then
remove switch from steering column. 5. Reverse procedure to install. During installation, gently
push up on switch to take up slack on rod.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
Headlamp Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 438
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 439
Headlamp Switch: Electrical Diagrams
Headlamp Switch & Horn System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 440
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 441
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 442
Headlamp Switch: Service and Repair
Headlamp switch removal
1. Disconnect battery ground cable. 2. Remove headlight and accessory switch trim bezel. 3.
Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then
disconnect switch electrical connectors. 5. Remove switch knob and stem by depressing button on
switch. 6. Remove two headlight switch plate to switch plate assembly attaching screws, then the
headlight switch retainer and switch. 7. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Technical Service Bulletins > Turn Signal Switch - Canceling Pin Indexing
Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Canceling Pin Indexing
Models
1988 & 1989 AA-, AB-, AC-, AD-, AG-, AH-, AJ-, AK-, AL-, AM-, AN-, & AP-Body Equipped With
Non-tilt Steering Column
Subject
Turn Signal Switch Canceling
Index
ELECTRICAL
Date
January 30, 1989
No.
08-03-89
P-196
(C08-03-9) BODY CODE LEGEND
AA - Spirit/Acclaim AK - Aries/Reliant
AB - Dodge Ram/Van Wagon AL - Omni/Horizon
AC - Dynasty/New Yorker/Landau AM - Diplomat/Gran Fury/
AD - Dodge Ram Pickup/ Fifth Avenue
Ramcharger Sport Utility AN - Dodge Dakota/
AG - Daytona Dakota/Sport
AH - Lancer/LeBaron GTS AP - Shadow/Sundance
AJ - Lebaron
SYMPTOM/CONDITION
Turn signals do not cancel properly after the steering wheel has been removed and reinstalled.
REPAIR PROCEDURE
Anytime the steering wheel is removed and replaced on nontilt columns, there is the possibility that
the turn signals will not cancel properly until the pin in the steering wheel is properly indexed with
respect to the turn signal switch.
The following procedure should be used to ensure the turn signal cancel feature operates correctly.
1. Engage the turn signal lever in either the right turn or the left turn position.
2. While holding the turn signal lever to prevent movement, rotate the steering wheel two complete
turns (or until the wheel stops) in the direction opposite the direction of the turn signal lever.
Example: If the turn signal lever is moved downward to the left, rotate the steering wheel to the
right. If the turn signal lever was moved upward to the right, then rotate the steering wheel to the
left.
3. Release the turn signal lever and then return the steering wheel to the straight ahead position.
4. To check for proper canceling operation, engage the turn signal lever and then turn the steering
wheel at least one-half revolution in the same direction in which the turn signal switch is engaged.
5. Return the steering wheel to the straight ahead position. The turn signal switch should cancel at
this time.
6. Repeat Steps 4 and 5 to check the cancel feature in the opposite direction.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Technical Service Bulletins > Page 447
Turn Signal Switch: Service and Repair
Turn Signal/Hazard Warning Switch
1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering
wheel.
Steering column cover, silencer & reinforcement removal
3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot
in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever
electrical connectors. 6. On models equipped with standard column, proceed as follows:
a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove
washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to
washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then
remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws.
7. On models equipped with tilt column, proceed as follows:
a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove
ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control
lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control
lever shaft to full clockwise position, then remove shaft from washer/wiper switch.
Lock plate removal. Models w/tilt column
e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring
out of groove with a suitable screwdriver.
The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will
turn too easily and make removal difficult.
f. Remove lock plate, cancelling cam and upper bearing spring.
g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard
switch attaching screws, Place shift bowl in Low position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Technical Service Bulletins > Page 448
Turn signal switch replacement
8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up
from column while straightening and guiding wires
up through column opening.
9. Reverse procedure to install. Rearm airbag system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
Absolute Pressure Sensor: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13 > Page 459
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and
Fault Code 13
Absolute Pressure Sensor: Customer Interest Check Engine Lamp Comes On and Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and
Fault Code 13 > Page 464
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and
Fault Code 13 > Page 465
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and
Fault Code 13 > Page 466
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set
Absolute Pressure Sensor: Customer Interest MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption
Absolute Pressure Sensor: Customer Interest Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 475
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start
Hesitation/Tip In Sag/DTC 13
Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start
Hesitation/Tip In Sag/DTC 13 > Page 481
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp
Comes On and Fault Code 13
Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and
Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp
Comes On and Fault Code 13 > Page 486
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp
Comes On and Fault Code 13 > Page 487
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp
Comes On and Fault Code 13 > Page 488
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or
14 Set
Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption
Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption >
Page 497
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations
Barometric Pressure Sensor: Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 505
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Component Locations
Coolant Temperature Sensor/Switch (For Computer): Component Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Component Locations > Page 511
Engine Components
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 512
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 5 Coolant & charge temperature sensors
The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the
SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The
sensor provides a variable resistance which is proportional to coolant temperature. When the
engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and
increases engine idle speed to provide acceptable cold engine performance and allow quick warm
up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel
mixtures and lowers engine idle speed to provide proper exhaust emission control and increased
fuel economy.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Senior 105 in.lb
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 518
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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519
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Engine Components
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
523
Intake Air Temperature Sensor: Description and Operation
Fig. 5 Coolant & charge temperature sensors
The charge temperature switch, Fig. 5, is mounted in the intake manifold and measures the
temperature of the air/fuel mixture. This information is used by the SMEC to modify the air/fuel
mixture.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Switch > Component Information > Locations
Intake Air Temperature Switch: Locations
RH Side Of Air Cleaner Assembly
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Component Locations
Manifold Pressure/Vacuum Sensor: Component Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Component Locations > Page 531
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 532
Manifold Pressure/Vacuum Sensor: Description and Operation
Fig. 3 Manifold Absolute Pressure (MAP) sensor location
The MAP sensor, Fig. 3, is mounted in the engine compartment on the dash panel and monitors
intake manifold vacuum through a line connected to the intake plenum. The sensor converts
manifold vacuum (negative pressure) and barometric pressure into electrical signals and transmits
these signals to the SMEC. The SMEC uses these signals to monitor engine load and atmospheric
conditions in order to determine the correct air/fuel mixture for vehicle operating conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Page 533
Manifold Pressure/Vacuum Sensor: Service and Repair
1. Remove vacuum hose from sensor.
2. Remove sensor attaching screws, then the sensor.
3. Reverse procedure to install. Ensure proper installation of vacuum hose to sensor and sensor to
dash panel.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
On Exhaust Manifold
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Oxygen Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 539
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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Oxygen Sensor: Description and Operation
Fig. 4 Oxygen sensor
The oxygen sensor, Fig. 4, produces voltage signals when exposed to oxygen in the exhaust
gasses. The oxygen content in the exhaust gasses is directly proportional to the air/fuel mixture
entering the engine, and the voltage signal produced by the sensor is inversely proportional to the
amount of oxygen remaining in the exhaust gasses. The SMEC uses these signals to determine
air/fuel mixtures entering the engine. The oxygen sensor is mounted in the rear exhaust manifold,
and the sensing element must be heated by exhaust gasses before the sensor begins to produce
voltage signals. When exhaust gas oxygen content is high (lean mixtures), the sensor produces a
low voltage. When oxygen content is low (rich mixtures), the sensor produces a higher voltage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 541
Oxygen Sensor: Service and Repair
The oxygen sensor is to be removed using tool No. C-4907 or equivalent. After removal, clean
threads in exhaust manifold using an 18mm x 1.5 x 6E tap. If reinstalling the same sensor, apply a
suitable anti-seize to threads of sensor. New sensors are packaged with an anti-seize compound
already applied to the threads and no further application is required. When installing sensor, torque
to 20 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision
Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure
Revision
Models
1989 AS
Subject
Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI
Index
MISCELLANEOUS
Date
December 29, 1989
No.
26-34-89 P-13 (C26-34-9) BODY CODE LEGEND
AS - 1989 RAM VAN, CARAVAN, VOYAGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 546
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 547
DIAGNOSTIC MANUAL REVISION
Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This
revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH.
1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No.
81-699-9017. Pages 136 and 137.
Please affix these revised pages in your manual.
POLICY: Information Only
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 548
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 549
Throttle Position Sensor: Locations
LH Rear Corner Of Cylinder Head
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 552
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 553
Throttle Position Sensor: Description and Operation
The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The
sensor produces a voltage signal which increases and decreases according to throttle position. The
SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide
open throttle, acceleration and deceleration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 554
Throttle Position Sensor: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle
body mounting screws.
3. Lift TPS from throttle shaft, then remove O-ring.
4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw
to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 563
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 564
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 565
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change > Page 571
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change > Page 572
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 577
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 578
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 579
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change > Page 585
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change > Page 586
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 589
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 590
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 591
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > PRNDL Switch > Page 594
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Description and Operation > Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Description and Operation > Transmission Range Sensor > Page 597
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > Sensor, Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > Sensor, Transmission Range > Page 600
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > Sensor, Transmission Range > Page 601
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > Sensor, Transmission Range > Page 602
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
LH Side Of Engine Compartment.
Upper LH Corner Of Transaxle
Applicable to: 1989 w/Electronic Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 608
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 609
Vehicle Speed Sensor: Description and Operation
The distance sensor is located in the transaxle extension housing and signals vehicle motion to the
SMEC by generating eight pulses per axle shaft revolution. The SMEC uses this signal along with
signals from the throttle position sensor to determine between a closed throttle deceleration and a
normal idle condition, thereby allowing the SMEC to maintain desired control of the AIS motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision
Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure
Revision
Models
1989 AS
Subject
Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI
Index
MISCELLANEOUS
Date
December 29, 1989
No.
26-34-89 P-13 (C26-34-9) BODY CODE LEGEND
AS - 1989 RAM VAN, CARAVAN, VOYAGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 615
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 616
DIAGNOSTIC MANUAL REVISION
Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This
revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH.
1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No.
81-699-9017. Pages 136 and 137.
Please affix these revised pages in your manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 617
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 618
Throttle Position Sensor: Locations
LH Rear Corner Of Cylinder Head
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 621
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 622
Throttle Position Sensor: Description and Operation
The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The
sensor produces a voltage signal which increases and decreases according to throttle position. The
SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide
open throttle, acceleration and deceleration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 623
Throttle Position Sensor: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle
body mounting screws.
3. Lift TPS from throttle shaft, then remove O-ring.
4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw
to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 629
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Senior 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 635
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 636
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Locations
Ignition Switch: Locations
I/P, Cowl & Steering Column Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 640
Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 641
Ignition Switch: Service and Repair
Fig. 10 Ignition switch replacement
1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES.
2. Remove left lower instrument panel cover.
3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle.
4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts.
5. Lower column and disconnect ignition switch electrical connector.
6. Position ignition lock cylinder in Lock position.
7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder
assembly.
8. Remove two ignition switch attaching screws, then the switch.
9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Testing and Inspection
Clutch Switch: Testing and Inspection
Clutch (Inhibitor) Switch Test
1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end
of switch terminal.
2. Connect a test light to remaining terminal end and ground.
3. Test light should be on when pedal is in normal position and off when pedal is depressed.
4. If above step is not as specified, replace clutch switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Locations
Ignition Switch: Locations
I/P, Cowl & Steering Column Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Locations > Page 649
Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Locations > Page 650
Ignition Switch: Service and Repair
Fig. 10 Ignition switch replacement
1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES.
2. Remove left lower instrument panel cover.
3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle.
4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts.
5. Lower column and disconnect ignition switch electrical connector.
6. Position ignition lock cylinder in Lock position.
7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder
assembly.
8. Remove two ignition switch attaching screws, then the switch.
9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > 3 Speed A/T
Neutral Safety Switch: Locations 3 Speed A/T
Neutral/Park Safety Switch
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > 3 Speed A/T > Page 655
Neutral Safety Switch: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > 3 Speed A/T > Page 656
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions
Neutral Safety Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 659
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 660
Neutral Safety Switch: Electrical Diagrams
3 Speed A/T
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
4 Speed A/T
The Neutral Safety Switch wiring is part of the starting system circuit. See: Starting and
Charging/Starting System/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Description and Operation > 3 Speed A/T
Neutral Safety Switch: Description and Operation 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
- It provides ground for the starter solenoid circuit through the selector lever in only Park and
Neutral positions.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Description and Operation > 3 Speed A/T > Page 663
Neutral Safety Switch: Description and Operation 4 Speed A/T
The Neutral Safety Switch sends a signal to the EATX control module and the engine control
module, controlling starter relay operation when the transaxle is in any gear other than Park or
Neutral.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Testing and Inspection > 3 Speed A/T
Neutral Safety Switch: Testing and Inspection 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Testing and Inspection > 3 Speed A/T > Page 666
Neutral Safety Switch: Testing and Inspection 4 Speed A/T
The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract
codes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Service and Repair > 3 Speed A/T
Neutral Safety Switch: Service and Repair 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Service and Repair > 3 Speed A/T > Page 669
Neutral Safety Switch: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Service and Repair > 3 Speed A/T > Page 670
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the
transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 684
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 685
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 686
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor
- Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor
- Production Change > Page 692
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor
- Production Change > Page 693
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed
Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed
Gear Engagement > Page 698
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed
Gear Engagement > Page 699
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed
Gear Engagement > Page 700
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 706
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 707
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid
and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid
and Pressure Switch Assembly > Page 710
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid
and Pressure Switch Assembly > Page 711
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid
and Pressure Switch Assembly > Page 712
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page
715
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation >
Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation >
Transmission Range Sensor > Page 718
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor,
Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor,
Transmission Range > Page 721
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor,
Transmission Range > Page 722
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor,
Transmission Range > Page 723
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 732
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
737
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
738
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
739
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise
Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise
Control > Page 745
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
> Page 750
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
> Page 751
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
> Page 752
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 753
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed
Sensor
Transmission Speed Sensor: Description and Operation Output Speed Sensor
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed
Sensor > Page 756
Transmission Speed Sensor: Description and Operation Turbine Speed Sensor
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque
convertor turbine).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 757
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation
Transmission Temperature Sensor/Switch: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Locations
Heated Glass Element Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations
Power Window Switch: Locations
Front Door Components
In Front Door Armrest
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection > Power Window Switch Test
Power Window Switch: Testing and Inspection Power Window Switch Test
Left Power Window Switch Continuity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection > Power Window Switch Test > Page 770
Right Power Window Switch Continuity
1. If the failure is in the right side door, remove the right power window switch from the door trim
panel.
2. Connect jumper wires to the right power window switch connector as shown. The jumper wires
take the place of a good switch in the inactive position.
3. Using the drivers side power window switch, activate the windows up and down. If the power
windows now operate properly, replace the passenger side switch. If the power windows still do not
operate, go to step 4.
4. Remove the drivers side power window switch from the door trim panel.
5. Connect jumper wires to the power window switch electrical connector as shown. If the power
window system operates with the jumper wires connected, the power window switch is defective
and needs to be replaced. If the power window system doesn't work with the jumper wires
connected, check the wiring harness from the switch to the window lift motor for an open circuit.
See: Windows and Glass/Windows/Power Window Motor/Testing and Inspection/Window Lift Motor
Test
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection > Power Window Switch Test > Page 771
Power Window Switch: Testing and Inspection Switch Voltage Test
Left Power Window Switch Continuity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection > Power Window Switch Test > Page 772
Right Power Window Switch Continuity
NOTE: The following test determines whether voltage is continuous through the wiring harness to
the power window switch.
1. Remove the power window switch from the door trim panel.
2. Separate the multiple terminal block on the wiring harness from the power window switch.
3. Connect one lead of a test light to the black wire terminal and the other lead to the tan wire
terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning
properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check
for an open in the wiring harness.
4. If the wiring circuit is functioning properly, See: Windows and Glass/Windows/Power Window
Motor/Testing and Inspection/Window Lift Motor Test
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection > Page 773
Power Window Switch: Service and Repair
1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect
wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
Engine Compartment Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Service and Repair
Windshield Washer Switch: Service and Repair
Fig. 2 Ignition lock removal. Models w/tilt column
FRONT
Standard Column
Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper
switch replacement procedure.
Tilt Column
1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES.
2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning
Switch, Replace."
3. Remove ignition key lamp.
4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock
cylinder release holes and push inward until spring loaded lock cylinder retainers release.
5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge
spring and pulling straight out. Use caution not to drop switch into steering column.
6. Remove three switch housing cover attaching screws, then the housing cover.
7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if
necessary.
8. Reverse procedure to install. Rearm airbag system.
REAR
1. Disconnect battery ground cable.
2. Remove switch plate bezel.
3. Remove four screws attaching switch plate to lower panel.
4. Pull switch assembly rearward, then disconnect switch electrical connectors.
5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Locations
Wiper Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Locations > Page 784
Wiper Switch: Testing and Inspection
Fig. 11 Two Speed Wiper Switch Continuity Chart
Fig. 12 Intermittent Wiper Switch Continuity Chart
1. Disconnect electrical connector to switch at body wiring harness connector. 2. Operate switch in
all positions, and check continuity between terminals with an ohmmeter. The first (clockwise)
position is the Off position.
Next is the slide for the Delay wipe, with counterclockwise rotation, reducing the delay. Low is the
next detent position. High is the full counterclockwise detent position. In any wiper mode, if the
knob is pushed in all the way, the washer circuit will be completed.
3. If continuity is not as specified in charts, replace switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Locations > Page 785
Wiper Switch: Service and Repair
Fig. 2 Ignition lock removal. Models w/tilt column
FRONT
Standard Column
Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper
switch replacement procedure.
Tilt Column
1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES.
2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning
Switch, Replace."
3. Remove ignition key lamp.
4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock
cylinder release holes and push inward until spring loaded lock cylinder retainers release.
5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge
spring and pulling straight out. Use caution not to drop switch into steering column.
6. Remove three switch housing cover attaching screws, then the housing cover.
7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if
necessary.
8. Reverse procedure to install. Rearm airbag system.
REAR
1. Disconnect battery ground cable.
2. Remove switch plate bezel.
3. Remove four screws attaching switch plate to lower panel.
4. Pull switch assembly rearward, then disconnect switch electrical connectors.
5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear
Alignment: Customer Interest Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 795
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 796
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear
Alignment: All Technical Service Bulletins Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 802
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 803
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 804
Alignment: By Symptom
Technical Service Bulletin # 020790 Date: 901105
Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 805
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 806
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Technical Service Bulletin # 020790 Date: 901105
Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 807
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Fig. 3-Shim Installation for Positive Camber
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 808
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten
adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 809
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Technical Service Bulletin # 020790 Date: 901105
Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 810
Fig. 2-Shim Installation for Toe-in
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 811
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten
adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Technical Service Bulletin # 020790 Date: 901105
Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 812
reverse sign convention; a total toein on direct reading charts is actually toe-out while driving.
Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Fig. 3-Shim Installation for Positive Camber
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 813
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten
adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 814
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment
Specifications
Front Wheel Alignment Specifications
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment
Specifications > Page 817
Rear Wheel Alignment Specifications
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment
Alignment: Service and Repair Front Alignment
Camber
Fig. 1 Camber adjustment
To adjust camber, loosen cam and through bolts. Rotate upper cam bolt to move top of wheel in or
out to achieve specified camber angle. Torque cam bolt nut to 75 ft. lbs. plus an additional 1/4 turn.
Caster
The caster angle on these vehicles cannot be adjusted.
Preliminary Inspection
Prior to wheel alignment, ensure tires are at recommended pressure, are of equal size and have
approximately the same wear pattern. Check front wheel and tire assembly for radial runout and
inspect lower ball joints and steering linkage for looseness. Check front and rear springs for
sagging or damage. Front suspension inspections should be performed on a level floor or
alignment rack with fuel tank at capacity and vehicle free of luggage and passenger compartment
load.
Before each alignment reading, the vehicle should be bounced an equal number of times from the
center of the bumper alternating first from the rear, then the front, and releasing at bottom of down
cycle.
Toe Adjustment
Fig. 2 Toe-in adjustment
To adjust toe-in, center steering wheel and hold in position with a suitable tool. Loosen tie rod
locknuts and rotate rod, to adjust toe-in to specifications. Use care not to twist steering gear rubber
boots. Torque tie rod locknuts to 55 ft. lbs. Adjust position of steering gear rubber boots. Remove
steering wheel holding tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment >
Page 820
Alignment: Service and Repair Rear Alignment
Rear wheel alignment is not adjustable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations
Fuel Pressure Test Port: Locations
System not equipped with fuel pressure test port. (To test fuel pressure tee into system with
adapter.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Adjustments
Air/Fuel Mixture: Adjustments
CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw.
Never attempt to adjust idle mixture using this screw!
Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not
adjustable.
If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE
Computers and Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
IDLE SPEED
Idle speed adjustment is electronically controlled by the Automatic Idle Speed (AIS) Motor and is
not adjustable. For diagnosis of incorrect idle speed, refer to COMPUTERIZED ENGINE
CONTROLS.
IDLE SPEED
Automatic .............................................................................................................................................
.................................................................. 800 RPM Manual ..............................................................
...................................................................................................................................................... 800
RPM
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications > Page 832
Idle Speed: Testing and Inspection
1. Remove air cleaner assembly, then plug heated air door vacuum hose.
2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan
cycles ON and OFF at least once. STOP engine.
3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and
ensure basic timing is set to 12° BTDC.
4. STOP engine and reconnect coolant temperature sensor wire.
5. Disconnect PCV valve hose from intake manifold nipple.
6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV
nipple.
7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1
minute.
8. Using scanner, place read/hold switch in read position and depress ATM button until code 70
appears.
9. Place read/hold switch to hold position, then the following should occur: a.
AIS motor will fully close.
b. Idle spark advance will become fixed.
c. Idle fuel will become enriched.
d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example,
display 95 equals 95 x 10 which indicates 950 rpm.
10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is
satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE
PROCEDURES. Retest minimum air flow after throttle body cleaning.
11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install
PCV valve hose.
12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door
vacuum hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications > Page 833
Idle Speed: Adjustments
CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw.
Never attempt to adjust idle speed using this screw, unless directed to do so in a service
procedure.
Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air
Control (IAC) motor, and is not adjustable.
If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if
deposits are visible. Perform Minimum Idle Air Flow Test if applicable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
1. Loosen gas cap and allow tank pressure to release.
2. Remove wiring harness connector from any injector, then ground one injector terminal.
3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery
for approximately 10 seconds and release system pressure.
4. Remove jumper wires and service fuel system as required.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications > Cylinder Location
1988-1996 3.0L (182)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications > Cylinder Location > Page 842
Distributor Cap From The Top - Includes Connections Inside The Cap. (Round Terminals Are Plug
Wire Connections On The Top Of The Cap.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Number One Cylinder: Locations
1988-1996 3.0L (182)
3.0L Except Stealth
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks
and Indicators > System Information > Diagrams
Timing Marks and Indicators: Diagrams
TIMING MARK 3.0L
Timing Scale Above Crank Pulley--Viewed From Front Of Car
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications
Ignition Cable: Specifications
Minimum
..................................................................................................................................................... 250
ohms per inch (3,000 ohms per foot)
Maximum
............................................................................................................................................... 1,000
ohms per inch (12,000 ohms per foot)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component
Information > Specifications
Distributor: Specifications
Distributer Adapter ...............................................................................................................................
.......................................... 14 Nm (120 in lbs) Distributer Housing Bolt .............................................
.................................................................................................................... 15 Nm (130 in lbs)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component
Information > Specifications > Page 856
Distributor: Locations
Distributor Hold-Down
The Optical Distributor is located at the back of the engine, behind the right-hand cylinder head.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component
Information > Specifications > Page 857
Distributor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap Specifications
Spark Plug: Specifications Gap Specifications
Refer to the Vehicle Emission Control Information (VECI) label, (under hood).
If label is gone, or not readable, verify system and use the following specification.
Plug Gap ..............................................................................................................................................
.................... 0.9 to 1.1 mm (0.039 to 0.044 in)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap Specifications > Page 862
Spark Plug: Specifications Tightening Specifications
Spark Plug Torque ...............................................................................................................................
...................................................... 28 Nm (20 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
SERVICE SPECIFICATIONS
Compression pressure .....................................................................................................................
840 kPa (178 psi) +/- 100 kPa (14 psi) @ 250-400 rpm Maximum variation .......................................
..............................................................................................................................................................
.... 25% Manifold vacuum ....................................................................................................................
........................................................... 520 mmHg (20 in.Hg.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 866
Compression Check: Testing and Inspection
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the
throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure
gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the
compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
NOTE: Correct engine compression pressures should be 178 psi +/- 14 psi, Maximum cylinder
deviation 25%
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all
times.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 870
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters. No provision for adjustment is provided.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Testing and Inspection
Timing Belt: Testing and Inspection
ABNORMAL NOISES FROM TIMING BELT
Incorrect Belt Tension
Timing belts which are too loose or too tight are prone to making a humming sound, especially on
heavy deceleration. Inspect the timing belt and re-adjust the tension.
Pulley or Belt Rubbing on Cover
A rubbing or whining sound can occur when the pulleys (or belt) are rubbing against the timing
covers. Remove the covers and inspect for wear. If the timing belt shows any signs of wear or fraying along
the outer edge it should be replaced.
- Inspect the pulleys for proper alignment. An incorrectly placed washer or spacer may move one
pulley out of alignment with the rest.
- Verify all pulleys have no lateral movement (wobble) . Replace any pulley which wobbles.
- Verify the timing cover is not warped. The cover should be replaced if warped.
- Verify the timing cover rubber gasket is properly installed.
Incorrect Type of Timing Belt
Timing belt teeth are available in several different types. Compare the new belt to the old one and
verify the teeth are the same shape. Timing belt types are not interchangeable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks
Timing Belt: Service and Repair Initial Checks
INITIAL CHECKS (PRIOR TO REMOVAL)
PURPOSE
Checking and recording the ignition timing and manifold vacuum level before and after the timing
belt replacement allows for two assurances: Initial conditions are correct.
- Verifies the quality of the job after the belt has been installed.
WHY
Ignition Timing
Ignition timing is the position of the piston on its compression stroke when the ignition coil fires the
associated sparkplug.
Ignition timing is affected by two sources. Physical rotation of the distributor.
- Alignment of the camshaft and crankshaft via the timing belt.
Prior to replacing the timing belt it is very important to verify that this relationship is correct. If the
timing belt is installed correctly the after-repairs timing check should be within 2 degrees of the
pre-repairs timing check.
NOTE: Minor differences, +/- 2 degrees may result from original belt stretching as it aged.
If the timing belt is initially installed incorrectly, the prerepairs ignition timing may not be correct,
and the after-repairs timing will differ greatly from the initial.
Checking the timing before and after the job will help prevent confusion and verify the job was done
correctly.
Notes on Timing: An ignition timing of 0 degrees BTDC (Before Top Dead Center) implies that the ignition coil fires
the spark exactly as the piston reaches its highest position (top dead center).
- An ignition timing of 10 degrees BTDC implies that the spark is triggered 10 degrees of crankshaft
rotation Before to the piston reaching top dead center.
- An ignition timing of 10 degrees IT'D implies that the spark is triggered 10 degrees of crank shaft
rotation After the piston reaches top dead center.
Manifold Vacuum
If the camshaft is out of alignment with the crankshaft, the intake and exhaust valves will not open
and close at the optimum times. This will reduce the volumetric efficiency of the engine and thus
reduce the manifold vacuum level.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 876
NOTE: The ignition timing will also affect the manifold vacuum levels, verify the timing is correct
prior to measuring the vacuum.
If the after-repair vacuum level is lower than the pre-repairs level this would be an indication that
the timing belt may not be installed correctly.
NOTE: The vacuum checks should be made at similar engine speeds and temperatures.
- Check "manifold vacuum" at a source downstream of the throttle plates.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 877
Timing Belt: Service and Repair Pre-Installation Inspection
PRE-INSTALLATION INSPECTION
- Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or
damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt
mating surface will require the pulley to be replaced.
- Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp,
causing the pulleys or belts to rub against the inside of the cover.
- Inspect the tensioner and water pump pulleys for wobble or looseness. The pulleys should spin
freely with no rough spots or lateral (side-to-side) movement.
- Inspect the tensioner and water pump pulley surfaces. They should be clean and free of nicks and
burrs. If any damage is noted the pulleys should be replaced.
- Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage
should be replaced.
WARNING: Oil leakage will damage the new timing belt.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 878
Timing Belt: Service and Repair Timing Belt Removal and Installation
Removal
NOTE: Always carefully inspect the Water Pump when replacing the Timing Belt, as the pump is
timing belt driven.
Fig. 5 Accessories & mounting brackets removal & installation
1. Disconnect battery ground cable.
Air Conditioning Belt
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 879
Alternator/Power Steering Belt
2. Remove accessory drive belts.
a Loosen adjusting lock nut on A/C belt adjuster, Turn adjusting jack screw counterclockwise to
reduce belt tension.
b Install breaker bar into 1/2 square opening in tensioner on Alternator/Power Steering belt. Rotate
tensioner counterclockwise to remove belt.
3. Remove A/C compressor, alternator, power steering pump, tensioners and mounting brackets as
shown in Fig. 5, and set aside.
Right Inner Splash Shield - Typical
4. Raise and support vehicle, then remove right inner splash shield.
Fig. 6 Crankshaft pulley removal
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 880
5. Remove crankshaft drive pulleys and torsional damper, Fig. 6, then lower vehicle and position a
suitable jack under engine.
Fig. 7 Engine mount removal - Typical
6. Remove engine mount insulator from engine mount bracket, raise engine slightly, then remove
engine mount bracket as shown in Fig. 7.
Fig. 8 Timing belt cover removal
7. Remove timing belt covers as shown in Fig. 8. 8. If belt is to be reused, mark belt running
direction for reassembly reference.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 881
Fig. 9 Timing Belt Routing
9. Loosen timing belt tensioner, Fig. 9, then remove timing belt.
10. Remove crankshaft sprocket flange, if necessary. 11. Remove camshaft sprocket attaching
bolts, then the sprockets, if necessary.
Camshaft Sprockets
12. Install camshaft sprockets, then using camshaft sprocket holder tool MB990775, torque bolts to
73 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 882
Fig. 10 Positioning timing belt tensioner
13. Install timing belt tensioner and spring. Rotate tensioner counterclockwise, Fig. 10, then
temporarily tighten bolt. 14. Install timing belt on crankshaft sprocket first, while keeping belt tight
on tension side, then position belt over front camshaft sprocket, Fig. 9. 15. Then, install belt on
water pump pulley and rear camshaft sprocket and finally on the timing belt tensioner, Fig. 9. 16.
Rotate front camshaft sprocket in opposite direction and check that all timing marks align, Fig. 9.
17. Install crankshaft sprocket flange, then loosen tensioner bolt to allow spring to tension belt.
Rotate crankshaft two complete revolutions, in
direction of normal rotation and check timing marks.
18. Tighten tensioner bolt to 23 ft. lbs. 19. Install timing belt covers as shown in Fig. 8. 20. Install
engine brackets, pulleys, and accessories as shown in Fig. 5, then the drive belts.
Installation
NOTE: Always carefully inspect the Water Pump when replacing the Timing Belt, as the pump is
timing belt driven.
Camshaft Sprockets
1. Install camshaft sprockets, then using camshaft sprocket holder tool MB990775, torque bolts to
73 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 883
Fig. 10 Positioning timing belt tensioner
2. Install timing belt tensioner and spring. Rotate tensioner counterclockwise, Fig. 10, then
temporarily tighten bolt.
Fig. 9 Timing Belt Routing
3. Install timing belt on crankshaft sprocket first, while keeping belt tight on tension side, then
position belt over front camshaft sprocket, Fig. 9. 4. Then, install belt on water pump pulley and
rear camshaft sprocket and finally on the timing belt tensioner, Fig. 9. 5. Rotate front camshaft
sprocket in opposite direction and check that all timing marks align, Fig. 9. 6. Install crankshaft
sprocket flange, then loosen tensioner bolt to allow spring to tension belt. Rotate crankshaft two
complete revolutions, in
direction of normal rotation and check timing marks.
7. Tighten tensioner bolt to 23 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 884
Fig. 8 Timing belt cover removal
8. Install timing belt covers as shown in Fig. 8.
Fig. 5 Accessories & mounting brackets removal & installation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks >
Page 885
Air Conditioning Belt
Alternator/Power Steering Belt
Fig. 7 Engine mount removal - Typical
9. Install engine brackets, pulleys, and accessories as shown in Fig. 5, then the drive belts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 886
Timing Belt: Tools and Equipment
RECOMMENDED TOOLS
- Floor jack (for supporting the engine while removing the front engine mount).
- Timing light (for measuring timing before and after).
- Vacuum gauge (for measuring engine vacuum levels before and after).
Crankshaft Pulley Removal
- Crankshaft Holding Tool MD998784 (used in conjunction with an old drive belt), or an air powered
impact gun (for removing the crankshaft bolt).
Timing Belt Tensioner Release
- Large flat blade screw driver (for moving timing belt tensioner).
- Torque Wrenches: Low Range (0-50 ft-lb) for covers and brackets.
- High Range (0-150 ft-lb) for crankshaft pulley bolt.
- Full set of Metric sockets and wrenches.
- Fender covers.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information
Timing Belt: Fundamentals and Basics General Information
TIMING BELT, GENERAL INFORMATION
PURPOSE
The timing belt synchronizes (times) the opening and closing of the intake and exhaust valves with
the movement/stroke of the pistons. The timing belt also matches the rotation of the distributor with
the movement of the pistons.
OPERATION
The crankshaft represents the movement of the pistons while the camshaft controls the opening
and closing of the valves. The timing belt connects the crankshaft to the camshaft and uses the
rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of
the crankshaft the camshaft is rotated only once.
Why 2:1
In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and
exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must
rotate two full revolutions.
The camshaft controls the opening and closing of the valves. During the four piston strokes of an
engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This
requires only one revolution of the camshaft.
NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves
will open and close only during the exhaust stroke. During the compression and power strokes the
valves remain closed.
How
This 2 to 1 reduction is accomplished by making the circumference of the camshaft pulley twice as
large as the crankshaft pulley. This allows the smaller crankshaft to complete two revolutions while
the larger camshaft completes only one revolution.
NOTE: The distributor also requires only one rotation for every two rotations of the crankshaft.
FIRST INDICATIONS OF A BROKEN BELT
1. The engine will immediately die or fail to start. 2. When attempting to restart the engine, the
cranking speed (rpm) will be unusually fast. 3. The sound of the engine while attempting to restart
will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir..." cranking sound
it will sound more like "RirRirRirRir" with no detectable rhythm.
Why When the timing belt brakes the camshaft and distributor quit rotating.
- Without distributor rotation the ignition system stops producing spark and the engine immediately
dies or fails to start.
- Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This
prevents the pistons from developing compression which also causes the engine to die. This lack
of compression also produces the unusually fast and non- rhythmic cranking speed when
attempting to restart the engine.
NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each
piston begins its compression stroke.
VERIFYING TIMING BELT IS BROKEN
Check for camshaft rotation while cranking the engine (with the starter or by hand, using the
crankshaft bolt).
WARNING: When rotating the crankshaft by hand always disconnect the battery.
Camshaft rotation can be verified by: Remove oil filler cap and check if camshaft is visible.
- Remove valve cover and directly observe camshaft.
- Remove distributor cap and check for rotor rotation (the rotor is driven by the camshaft)
- Remove upper timing belt cover and check camshaft pulley rotation and belt integrity.
Other Indications the Timing Belt may be broken. No ignition spark.
- Very low compression (<15 psi) on all cylinders. Due to the low compression the following
additional symptoms may be present. While attempting to start the car, the battery strength remains high for an unusually long length of
time.
- The sound of the engine while attempting to restart will be different than normal. Instead of the
usual rhythmic "Rir.. .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no
detectable rhythm.
NOTE: For an experienced technician this unique sound will often be the initial symptom that leads
to a more in-depth check of the timing belt.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 889
OTHER RELATED PROBLEMS
The Timing Belt has Jumped Teeth If the belt is excessively worn, loose, or missing teeth it is possible for the belt to jump teeth on the
crankshaft.
- A belt which is off by just one tooth will cause an engine to run very poorly or not run at all.
A belt which is off by more than one tooth will generally prevent the engine from starting.
To verify the problem, remove the timing belt covers and check the crankshaft and camshaft
alignment marks.
The Camshaft is Seized
- A seized camshaft will produce the same symptoms as a broken timing belt.
WARNING: Rotating the camshaft with the timing belt removed on an interference engine can
result in additional valve damage.
INTERFERENCE/FREE RUNNING
Interference - Upon reaching Top Dead Center a piston will impact a valve which is fully open. This
situation occurs when the timing belt breaks and a valve is left fully open while the pistons continue
to operate.
NOTE: This engine is an Interference design.
Free Running - The engine has been designed such that should the timing belt break there will still
be clearance between a fully open valve and a piston at TDC.
Valve Damage - Interference engines will generally bend intake or exhaust valves when a timing
belt is broken. When a timing belt breaks the rotational momentum of the camshaft will cause
several valves to open and close out of sequence with the movement of the pistons.
Any valve which is left open when the associated piston reaches TDC will be struck and bent. Bent
valves will generally stick in a partially open position, resulting in a loss of vacuum and
compression on that cylinder.
If a timing belt breaks during normal city or highway driving the probability that an interference
engine will bend at least one valve is very high.
NOTE: If a timing belt breaks, an interference type engine will not always bend or damage valves.
If the timing belt breaks during start-up with camshaft remaining in a position where no valve is fully
open there will be no valve damage.
Free running engines will generally not bend or damage valves when a timing belt is broken.
However the design clearance between a fully open valve and a piston at TDC may be quite small
(<0.020 inches) . A build up of carbon on top of the piston in conjunction with improperly adjusted
valve clearances can result in a free running engine bending valves when the timing belt breaks.
VERIFYING VALVE DAMAGE
Install a new timing belt with the camshaft and crankshaft aligned properly and attempt to start the
engine. If the engine starts and runs smoothly with steady high vacuum levels, the valves are not
damaged.
WARNING: Rotating the camshaft with the timing belt removed on an interference engine can
result in additional valve damage.
If the engine fails to start or runs roughly with the manifold vacuum reading rapidly oscillating over
a 4-6 inch range there may be valve damage.
NOTE: Verify that the crankshaft and camshaft are aligned properly. A timing belt which is off Dust
one tooth may produce similar performance symptoms.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 890
Remove the valve cover and inspect the valve clearances. A valve which is bent will be stuck in the
open position or will have an excessively larger clearance.
Perform a compression check or a cylinder leak down check. Cylinders with bent valves will have
very low compression (<50.0 psi) and will not hold pressure.
If valve damage is detected the cylinder head will have to be removed and the damaged valves
replaced. Also inspect top of the pistons for damage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 891
Timing Belt: Fundamentals and Basics Initial Preparations
INITIAL PREPARATIONS
Disconnect Battery
When working near or around the crankshaft/camshaft pulleys, accidentally engaging the starter
can result in serious personal injury and major engine damage.
The negative battery terminal should be disconnected prior to commencing work and should not be
reconnected until the timing belt is re-installed and the engine is ready to start.
Remove Front Tire
Access to lower timing belt components can be gained by removing the associated front tire and
working through the wheel well.
Fender Covers
Fender covers will prevent damage to the vehicles finish while performing the job.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 892
Timing Belt: Fundamentals and Basics Positioning Crankshaft to Number 1 TDC
POSITIONING CRANKSHAFT TO #1 TDC, Compression
NOTE: If the timing belt is broken, pre-position only the crankshaft and ignore references in this
article to compression stroke, camshaft, and distributor position. Rotating the camshaft with a
broken timing belt may damage the valves.
WHY
Timing belt installation alignment marks correspond to the crankshaft positioned at #1 Top Dead
Center (TDC), during the compression stroke. Moving the crankshaft to this point prior to removing
the belt allows you to verify the original alignment of the crankshaft and camshaft. This also
reduces crank/cam pulley movement once the belt is removed which helps to minimize any
possible confusion.
The alignment marks may be dirty and difficult to locate. Pre-positioning the crankshaft will make it
easier to locate the marks.
HOW
- Remove the distributor cap and observe the position of the rotor.
- Using the crankshaft bolt, rotate the crankshaft until the distributor rotor is nearly pointing towards
the #1 cylinder position.
- Then slowly rotate the crankshaft until the timing indicator is pointing at the "0"/TDC degree mark.
NOTE: Remember that the crankshaft rotates twice for every rotation of the camshaft. The rotor
must be pointing towards #1 cylinder terminal when the timing mark reaches 0 degrees.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 893
Timing Belt: Fundamentals and Basics Removal and Installation Tips and Hints (Maintenance)
TIMING BELT REMOVAL
- Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be
removed to replace the timing belt it would be convenient to have any necessary replacement belts
on hand should any the drive belts show excessive wear.
- After the timing belt covers are removed, verify the camshaft and crankshaft are properly aligned.
- Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets
or covers could allow moisture and debris to enter the covers and damage the belt.
NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing
belt or between the belt and the pulley, resulting in the belt skipping teeth.
- When removing the engine mount, Slightly raise the engine with a floor jack. This will take the
weight of the engine off of engine mount bolts and will ease in removal.
CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of
wood or other soft material to prevent puncturing the oil pan.
TIMING BELT INSTALLATION
- When positioning or removing the camshaft and crankshaft pulleys, do not grasp the teeth of the
pulleys with pliers or any other metal object.
CAUTION: Any nick or burr left on the pulleys may result in premature belt failure.
- When installing the timing belt: Do not use any device to pry the belt over a pulley
- Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on.
- Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack
is left on the opposite side, when the tensioner is released the pulleys will turn and the belt
alignment will be incorrect.
- After installing and tensioning the belt, recheck the alignment of the camshafts and crankshaft.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 894
Timing Belt: Fundamentals and Basics
General Information
TIMING BELT, GENERAL INFORMATION
PURPOSE
The timing belt synchronizes (times) the opening and closing of the intake and exhaust valves with
the movement/stroke of the pistons. The timing belt also matches the rotation of the distributor with
the movement of the pistons.
OPERATION
The crankshaft represents the movement of the pistons while the camshaft controls the opening
and closing of the valves. The timing belt connects the crankshaft to the camshaft and uses the
rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of
the crankshaft the camshaft is rotated only once.
Why 2:1
In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and
exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must
rotate two full revolutions.
The camshaft controls the opening and closing of the valves. During the four piston strokes of an
engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This
requires only one revolution of the camshaft.
NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves
will open and close only during the exhaust stroke. During the compression and power strokes the
valves remain closed.
How
This 2 to 1 reduction is accomplished by making the circumference of the camshaft pulley twice as
large as the crankshaft pulley. This allows the smaller crankshaft to complete two revolutions while
the larger camshaft completes only one revolution.
NOTE: The distributor also requires only one rotation for every two rotations of the crankshaft.
FIRST INDICATIONS OF A BROKEN BELT
1. The engine will immediately die or fail to start. 2. When attempting to restart the engine, the
cranking speed (rpm) will be unusually fast. 3. The sound of the engine while attempting to restart
will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir..." cranking sound
it will sound more like "RirRirRirRir" with no detectable rhythm.
Why When the timing belt brakes the camshaft and distributor quit rotating.
- Without distributor rotation the ignition system stops producing spark and the engine immediately
dies or fails to start.
- Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This
prevents the pistons from developing compression which also causes the engine to die. This lack
of compression also produces the unusually fast and non- rhythmic cranking speed when
attempting to restart the engine.
NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each
piston begins its compression stroke.
VERIFYING TIMING BELT IS BROKEN
Check for camshaft rotation while cranking the engine (with the starter or by hand, using the
crankshaft bolt).
WARNING: When rotating the crankshaft by hand always disconnect the battery.
Camshaft rotation can be verified by: Remove oil filler cap and check if camshaft is visible.
- Remove valve cover and directly observe camshaft.
- Remove distributor cap and check for rotor rotation (the rotor is driven by the camshaft)
- Remove upper timing belt cover and check camshaft pulley rotation and belt integrity.
Other Indications the Timing Belt may be broken. No ignition spark.
- Very low compression (<15 psi) on all cylinders. Due to the low compression the following
additional symptoms may be present. While attempting to start the car, the battery strength remains high for an unusually long length of
time.
- The sound of the engine while attempting to restart will be different than normal. Instead of the
usual rhythmic "Rir.. .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no
detectable rhythm.
NOTE: For an experienced technician this unique sound will often be the initial symptom that leads
to a more in-depth check of the
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 895
timing belt.
OTHER RELATED PROBLEMS
The Timing Belt has Jumped Teeth If the belt is excessively worn, loose, or missing teeth it is possible for the belt to jump teeth on the
crankshaft.
- A belt which is off by just one tooth will cause an engine to run very poorly or not run at all.
- A belt which is off by more than one tooth will generally prevent the engine from starting.
- To verify the problem, remove the timing belt covers and check the crankshaft and camshaft
alignment marks.
The Camshaft is Seized
- A seized camshaft will produce the same symptoms as a broken timing belt.
WARNING: Rotating the camshaft with the timing belt removed on an interference engine can
result in additional valve damage.
INTERFERENCE/FREE RUNNING
Interference - Upon reaching Top Dead Center a piston will impact a valve which is fully open. This
situation occurs when the timing belt breaks and a valve is left fully open while the pistons continue
to operate.
NOTE: This engine is an Interference design.
Free Running - The engine has been designed such that should the timing belt break there will still
be clearance between a fully open valve and a piston at TDC.
Valve Damage - Interference engines will generally bend intake or exhaust valves when a timing
belt is broken. When a timing belt breaks the rotational momentum of the camshaft will cause
several valves to open and close out of sequence with the movement of the pistons.
Any valve which is left open when the associated piston reaches TDC will be struck and bent. Bent
valves will generally stick in a partially open position, resulting in a loss of vacuum and
compression on that cylinder.
If a timing belt breaks during normal city or highway driving the probability that an interference
engine will bend at least one valve is very high.
NOTE: If a timing belt breaks, an interference type engine will not always bend or damage valves.
If the timing belt breaks during start-up with camshaft remaining in a position where no valve is fully
open there will be no valve damage.
Free running engines will generally not bend or damage valves when a timing belt is broken.
However the design clearance between a fully open valve and a piston at TDC may be quite small
(<0.020 inches) . A build up of carbon on top of the piston in conjunction with improperly adjusted
valve clearances can result in a free running engine bending valves when the timing belt breaks.
VERIFYING VALVE DAMAGE
Install a new timing belt with the camshaft and crankshaft aligned properly and attempt to start the
engine. If the engine starts and runs smoothly with steady high vacuum levels, the valves are not
damaged.
WARNING: Rotating the camshaft with the timing belt removed on an interference engine can
result in additional valve damage.
If the engine fails to start or runs roughly with the manifold vacuum reading rapidly oscillating over
a 4-6 inch range there may be valve damage.
NOTE: Verify that the crankshaft and camshaft are aligned properly. A timing belt which is off Dust
one tooth may produce similar
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 896
performance symptoms.
Remove the valve cover and inspect the valve clearances. A valve which is bent will be stuck in the
open position or will have an excessively larger clearance.
Perform a compression check or a cylinder leak down check. Cylinders with bent valves will have
very low compression (<50.0 psi) and will not hold pressure.
If valve damage is detected the cylinder head will have to be removed and the damaged valves
replaced. Also inspect top of the pistons for damage.
Initial Preparations
INITIAL PREPARATIONS
Disconnect Battery
When working near or around the crankshaft/camshaft pulleys, accidentally engaging the starter
can result in serious personal injury and major engine damage.
The negative battery terminal should be disconnected prior to commencing work and should not be
reconnected until the timing belt is re-installed and the engine is ready to start.
Remove Front Tire
Access to lower timing belt components can be gained by removing the associated front tire and
working through the wheel well.
Fender Covers
Fender covers will prevent damage to the vehicles finish while performing the job.
Positioning Crankshaft to Number 1 TDC
POSITIONING CRANKSHAFT TO #1 TDC, Compression
NOTE: If the timing belt is broken, pre-position only the crankshaft and ignore references in this
article to compression stroke, camshaft, and distributor position. Rotating the camshaft with a
broken timing belt may damage the valves.
WHY
Timing belt installation alignment marks correspond to the crankshaft positioned at #1 Top Dead
Center (TDC), during the compression stroke. Moving the crankshaft to this point prior to removing
the belt allows you to verify the original alignment of the crankshaft and camshaft. This also
reduces crank/cam pulley movement once the belt is removed which helps to minimize any
possible confusion.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 897
The alignment marks may be dirty and difficult to locate. Pre-positioning the crankshaft will make it
easier to locate the marks.
HOW
- Remove the distributor cap and observe the position of the rotor.
- Using the crankshaft bolt, rotate the crankshaft until the distributor rotor is nearly pointing towards
the #1 cylinder position.
- Then slowly rotate the crankshaft until the timing indicator is pointing at the "0"/TDC degree mark.
NOTE: Remember that the crankshaft rotates twice for every rotation of the camshaft. The rotor
must be pointing towards #1 cylinder terminal when the timing mark reaches 0 degrees.
Removal and Installation Tips and Hints (Maintenance)
TIMING BELT REMOVAL
- Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be
removed to replace the timing belt it would be convenient to have any necessary replacement belts
on hand should any the drive belts show excessive wear.
- After the timing belt covers are removed, verify the camshaft and crankshaft are properly aligned.
- Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets
or covers could allow moisture and debris to enter the covers and damage the belt.
NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing
belt or between the belt and the pulley, resulting in the belt skipping teeth.
- When removing the engine mount, Slightly raise the engine with a floor jack. This will take the
weight of the engine off of engine mount bolts and will ease in removal.
CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of
wood or other soft material to prevent puncturing the oil pan.
TIMING BELT INSTALLATION
- When positioning or removing the camshaft and crankshaft pulleys, do not grasp the teeth of the
pulleys with pliers or any other metal object.
CAUTION: Any nick or burr left on the pulleys may result in premature belt failure.
- When installing the timing belt: Do not use any device to pry the belt over a pulley
- Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on.
- Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack
is left on the opposite side, when the tensioner is released the pulleys will turn and the belt
alignment will be incorrect.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 898
- After installing and tensioning the belt, recheck the alignment of the camshafts and crankshaft.
Removal and Installation Tips and Hints (Broken Belt)
TIMING BELT REMOVAL
- Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be
removed to replace the timing belt it would be convenient to have any necessary replacement belts
on hand should any the drive belts show excessive wear.
- After the timing belt covers are removed, align the camshaft and crankshaft.
1. Position the crankshaft to a safe position (approaching #1 Top Dead Center (TDC) with no
cylinder at or near top dead center) 2. Align the camshaft with its timing marks. 3. Rotate the
crankshaft to #1 TDC
WARNING: Valve damage will occur if any cylinder reaches Top Dead Center, while an associated
valve is at or near its fully open position.
NOTES When positioning the camshaft or crankshaft always rotate the shafts slowly and in small
increments, while frequently stopping to observe the relationship of the valves and pistons.
- With the spark plugs removed the crankshaft should rotate easily. If any resistance is felt,
immediately stop and verify that a piston is not striking a valve.
- Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets
or covers could allow moisture and debris to enter the covers and damage the belt.
NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing
belt or between the belt and the pulley, resulting in the belt skipping teeth.
- When removing the engine mount, slightly raise the engine with a floor jack. This will take the
weight of the engine off of engine mount bolts and will ease in removal.
CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of
wood or other soft material to prevent puncturing the oil pan.
INSPECTION
- Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or
damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt
mating surface will require the pulley to be replaced.
- Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp,
causing the pulleys or belts to rub against the inside of the cover.
- Inspect the tensioner/idler/water-pump pulleys for wobble or looseness. The pulleys should spin
freely with no rough spots or lateral (side-to-side) movement.
- Inspect the tensioner/idler/water pump pulley surfaces. They should be clean and free of nicks
and burrs. If any damage is noted the pulleys should be replaced.
- Inspect the water pump for signs of leakage, replace if necessary.
- Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage
should be replaced.
CAUTION: Oil leakage will damage the new timing belt.
TIMING BELT INSTALLATION
- When positioning or moving the camshaft and crankshaft pulleys, do not grasp the teeth of the
pulleys with pliers or any other metal object.
CAUTION: Any nick or burr left on the pulleys may result in premature belt failure.
- When installing the timing belt: Do not use any device to pry the belt over a pulley
- Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 899
- Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack
is left on the opposite side, when the tensioner is released the pulleys will turn and the belt
alignment will be incorrect.
- After installing and tensioning the belt, recheck the alignment of the camshafts and crankshafts.
Checking Engine Vacuum
CHECKING ENGINE VACUUM
Manifold vacuum readings (taken at a vacuum port downstream of the throttle plate) should be
steady and smooth. If valve damage has occurred the needle will rapidly fluctuate back and forth.
NOTE: Prior to checking vacuum, the ignition timing should be checked and adjusted. Ignition
timing will affect the vacuum levels.
To verify valve, perform a compression check or leak down check on all cylinders. Cylinders with
damaged valves will not develop compression and will not hold pressure.
If valve damage is detected the cylinder head will need to be removed.
Recommended Parts
RECOMMENDED PARTS
- New Timing Belt - Compare length, width, and shape of teeth to the old belt. They should match
exactly.
OPTIONAL, PENDING INSPECTION
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General
Information > Page 900
- Water Pump - Replacing the water pump requires removing the timing belt. A thorough
examination of the water pump while the timing belt is removed is highly recommended.
- Gasket Sealant - When removing the timing belt covers the gaskets may come unglued from the
covers.
- Camshaft and Crankshaft Seals - These seals are located behind the timing belt gears. Leakage
from these seals can rapidly deteriorate a new timing belt.
- Drive Belts - Drive belt removal is required to access the timing belt.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications
Drive Belt: Specifications
Fig. 23 Belt deflection check points
AIR CONDITIONING BELT
Belt deflection under a ten pound push or pull should be between 1/4 to 5/16 at locations shown in
Fig. 23. Measure deflection while applying tension to accessory, then tighten mounting mounts to
specification. Deflection on a new belt should be between 1/4 to 1/2; a belt is considered used after
15 minutes of engine operation, tension on a used belt should be 1/4 and 5/16 under a tension
pound load.
ACCESSORY BELT
Correct belt tension is 5/16 deflection between pulleys.
Fig. 24 Serpentine drive belt
SERPENTINE DRIVE BELT ROUTINGS
Refer to Fig. 24, for serpentine belt routing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 904
Fig. 24 Serpentine drive belt
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 905
Drive Belt: Adjustments
Fig. 23 Belt deflection check points
AIR CONDITIONING BELT
Belt deflection under a ten pound push or pull should be between 1/4 to 5/16 at locations shown in
Fig. 23. Measure deflection while applying tension to accessory, then tighten mounting mounts to
specification. Deflection on a new belt should be between 1/4 to 1/2; a belt is considered used after
15 minutes of engine operation, tension on a used belt should be 1/4 and 5/16 under a tension
pound load.
ACCESSORY BELT
Correct belt tension is 5/16 deflection between pulleys.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt
Drive Belt: Service and Repair A/C Belt
Fig. 27 A/C Pulley Removal
1. Loosen adjusting locknut, then turn jack-screw, Fig. 27, counterclockwise to reduce belt tension
and remove belt.
2. When reinstalling belt, adjust belt tension to 5/16 inch deflection between pulleys.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt > Page
908
Drive Belt: Service and Repair Accessory Drive Belt
WARNING: Belts must be checked with engine not running.
ACCESSORY DRIVE BELTS
Fig. 2 Air Conditioning Belt
A/C Belt
1. Loosen Adjusting Lock Nut Fig. 2. 2. Turn adjusting "jack" screw counterclockwise to reduce belt
tension. Remove belt. 3. Reinstall. 4. Adjust belt tension. A small spring scale can be used to
establish the ten-pound belt load. Belt deflection under a ten-pound push or pull should be
between 6 mm (1/4 in.) to 8mm (5/16 in.). Tighten pulley nut to 57 Nm (40 ft. lbs.) after adjustment.
Fig. 3 Alternator/Power Steering Belt
Alternator/Power Steering Belt
1. Install breaker bar into 1/2 square opening in tensioner. 2. Rotate tensioner counterclockwise to
remove (and install) belt Fig. 3.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt > Page
909
Drive Belt: Service and Repair Alternator & Power Steering Belt
Fig. 29 Alternator & Power Steering Belt Removal. 1989-90 Models
Fig. 30 Alternator & Power Steering Belt Removal. 1990-92 Models
1. Install breaker bar into square opening in tensioner, Figs. 29 and 30.
2. ^ On 1990 and earlier models, rotate tensioner counterclockwise to remove or install belt.
^ On 1991 and later models, rotate tensioner counterclockwise to remove or install belt.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature
Fluid Filter - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 919
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 920
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 921
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature
Fluid Filter - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 927
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 928
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 929
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13 > Page 935
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13
Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and
Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 940
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 941
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 942
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set
Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 091689 > Oct > 89 > Engine - Oil Consumption
Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 951
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13 > Page 957
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 962
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 963
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 964
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 973
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Fluid Drain and Refill
Fluid Filter - A/T: Service and Repair Fluid Drain and Refill
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2.
Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil
pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm
(165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602
through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and
service brakes applied, move selector lever momentarily to each
position, ending in the park or neutral position.
7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark.
CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil
(100°F). Upper holes for hot oil (180°F).
8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the
HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the
dipstick fill tube.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Fluid Drain and Refill > Page 976
Fluid Filter - A/T: Service and Repair Fluid & Filter Change
3 Speed Automatic
Fluid and filter changes are not required for average vehicle use. Severe usage such as
commercial type usage or prolonged operation in city traffic requires that fluid be changed and
bands adjusted every 15,000 miles.
1. Raise vehicle and support vehicle. Place a suitable drain pan below transmission oil pan. 2.
Loosen transmission oil pan attaching bolts and allow fluid to drain, then remove oil pan. 3.
Replace filter and adjust bands, if necessary. 4. Install oil pan and gasket. Torque attaching bolts to
40 inch lbs. 5. Add four quarts of approved automatic transmission fluid. 6. Start engine and allow
to idle for approximately six minutes, then with parking brake applied, move selector lever
momentarily to each position.
Place selector lever in Park and check fluid level. Add fluid to bring level to Add mark.
7. Recheck fluid level after transmission has reached normal operating temperature.
4 Speed Automatic
When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic
Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the
time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a
clean, dry cloth.
If the transaxle is disassembled for any reason, the fluid and filter should be changed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
and Repair
Fuel Pressure Release: Service and Repair
1. Loosen gas cap and allow tank pressure to release.
2. Remove wiring harness connector from any injector, then ground one injector terminal.
3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery
for approximately 10 seconds and release system pressure.
4. Remove jumper wires and service fuel system as required.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Locations
Water Pump And Coolant Tube
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 240395 > Jan > 95 > A/C System - Poor Cooling Performance
Hose/Line HVAC: Customer Interest A/C System - Poor Cooling Performance
NO: 24-03-95
GROUP: Heater & A/C
DATE: Jan. 27, 1995
SUBJECT: Revised Underbody Refrigerant Line Gasket
MODELS:
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1992 - 1995 (ES) Chrysler Voyager (European Market)
1989 (S) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH
AUXILIARY REAR A/C OPTION.
SYMPTOM/CONDITION:
Poor A/C system cooling performance.
DIAGNOSIS:
Check for low refrigerant charge and inspect the connection of the A/C underbody refrigerant lines
to the rear auxiliary A/C unit. If refrigerant is detected at the connection, perform the repair
procedure.
PARTS REQUIRED:
1 4798270 Gasket, Underbody Refrigerant Line
REPAIR PROCEDURE:
This bulletin involves installing a revised underbody refrigerant line gasket.
1. Recover any residual refrigerant in the A/C system.
2. Disconnect the A/C underbody refrigerant lines from the rear auxiliary A/C unit.
3. Inspect and clean the A/C plumbing surfaces that contact the gasket. Do not scratch the
surfaces.
4. Install the revised gasket, P/N 4798270. This gasket is rubber coated stainless steel.
5. Evacuate and recharge the A/C system using the procedure outlined in the appropriate Service
Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-45-62-90 .......................................................................................................
................................................................ 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 240490 > Sep > 90 > Air Conditioning System - Moaning/Growling
Noise
Hose/Line HVAC: Customer Interest Air Conditioning System - Moaning/Growling Noise
NO.: 24-04-90
GROUP: HEATER & A/C
DATE: Sept. 10, 1990
SUBJECT: Air Conditioning
System Noise - 3.OL Engine
MODELS: 1989 Dodge Caravan, Grand Caravan, Caravan C/V, Plymouth Voyager, Grand
Voyager, Chrysler Town & Country
SYMPTOM/CONDITION
Some vehicles equipped with the 3.OL engine may exhibit a moaning or growling noise when the
air conditioning system is on. This noise is caused by refrigerant gas pulsation being transmitted
through the A/C discharge line. This noise is NOT the fault of the A/C compressor.
DIAGNOSIS
Verify that the vehicle has a moaning or growling noise when the air conditioning is on. Inspect the
entire length of the discharge, suction and liquid lines for grounding. These lines should not touch
any sheet metal or underhood component. Also inspect these lines for grounding during engine roll
and where the lines go through the bulkhead. Inspect for proper foam or rubber isolation at all
brackets and the radiator support and correct as necessary. If the noise persists, proceed to the
following repair procedure. Remember, the compressor should not be replaced unless it has failed
the output test outlined in TSB 24-03-89 Revision A or is making metallic noises. REPLACING THE
COMPRESSOR FOR THE A/C DISCHARGE LINE NOISE WILL NOT CORRECT THE PROBLEM.
PARTS REQUIRED
1 4419464 A/C Discharge Line Assembly
REPAIR PROCEDURE
This procedure involves inspection and replacement of the A/C discharge line assembly with a
revised discharge line.
1. Check to see if the A/C discharge line muffler is approximately two inches from the condenser. If
so, remove the discharge line according to the procedure outlined in the service manual.
A/C systerns should be evacuated using an approved recovery station.
2. Install a new discharge line assembly (PN 4419464) that has a muffler located near the
compressor attachment flange.
3. Verify A/C operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
24-45-25-91 . . . . . . . . . . . . . . . . 1.2 Hrs.
Replace A/C Discharge Line Assembly
24-01-10-01 . . . . . . . . . . . . . . . . 0.2 Hrs. Additional Time Required When R12 Recovery Station Is
Used
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 240395 > Jan > 95 > A/C System - Poor Cooling
Performance
Hose/Line HVAC: All Technical Service Bulletins A/C System - Poor Cooling Performance
NO: 24-03-95
GROUP: Heater & A/C
DATE: Jan. 27, 1995
SUBJECT: Revised Underbody Refrigerant Line Gasket
MODELS:
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1992 - 1995 (ES) Chrysler Voyager (European Market)
1989 (S) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH
AUXILIARY REAR A/C OPTION.
SYMPTOM/CONDITION:
Poor A/C system cooling performance.
DIAGNOSIS:
Check for low refrigerant charge and inspect the connection of the A/C underbody refrigerant lines
to the rear auxiliary A/C unit. If refrigerant is detected at the connection, perform the repair
procedure.
PARTS REQUIRED:
1 4798270 Gasket, Underbody Refrigerant Line
REPAIR PROCEDURE:
This bulletin involves installing a revised underbody refrigerant line gasket.
1. Recover any residual refrigerant in the A/C system.
2. Disconnect the A/C underbody refrigerant lines from the rear auxiliary A/C unit.
3. Inspect and clean the A/C plumbing surfaces that contact the gasket. Do not scratch the
surfaces.
4. Install the revised gasket, P/N 4798270. This gasket is rubber coated stainless steel.
5. Evacuate and recharge the A/C system using the procedure outlined in the appropriate Service
Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-45-62-90 .......................................................................................................
................................................................ 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 240490 > Sep > 90 > Air Conditioning System Moaning/Growling Noise
Hose/Line HVAC: All Technical Service Bulletins Air Conditioning System - Moaning/Growling
Noise
NO.: 24-04-90
GROUP: HEATER & A/C
DATE: Sept. 10, 1990
SUBJECT: Air Conditioning
System Noise - 3.OL Engine
MODELS: 1989 Dodge Caravan, Grand Caravan, Caravan C/V, Plymouth Voyager, Grand
Voyager, Chrysler Town & Country
SYMPTOM/CONDITION
Some vehicles equipped with the 3.OL engine may exhibit a moaning or growling noise when the
air conditioning system is on. This noise is caused by refrigerant gas pulsation being transmitted
through the A/C discharge line. This noise is NOT the fault of the A/C compressor.
DIAGNOSIS
Verify that the vehicle has a moaning or growling noise when the air conditioning is on. Inspect the
entire length of the discharge, suction and liquid lines for grounding. These lines should not touch
any sheet metal or underhood component. Also inspect these lines for grounding during engine roll
and where the lines go through the bulkhead. Inspect for proper foam or rubber isolation at all
brackets and the radiator support and correct as necessary. If the noise persists, proceed to the
following repair procedure. Remember, the compressor should not be replaced unless it has failed
the output test outlined in TSB 24-03-89 Revision A or is making metallic noises. REPLACING THE
COMPRESSOR FOR THE A/C DISCHARGE LINE NOISE WILL NOT CORRECT THE PROBLEM.
PARTS REQUIRED
1 4419464 A/C Discharge Line Assembly
REPAIR PROCEDURE
This procedure involves inspection and replacement of the A/C discharge line assembly with a
revised discharge line.
1. Check to see if the A/C discharge line muffler is approximately two inches from the condenser. If
so, remove the discharge line according to the procedure outlined in the service manual.
A/C systerns should be evacuated using an approved recovery station.
2. Install a new discharge line assembly (PN 4419464) that has a muffler located near the
compressor attachment flange.
3. Verify A/C operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
24-45-25-91 . . . . . . . . . . . . . . . . 1.2 Hrs.
Replace A/C Discharge Line Assembly
24-01-10-01 . . . . . . . . . . . . . . . . 0.2 Hrs. Additional Time Required When R12 Recovery Station Is
Used
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
Use new brake fluid only, to top off the master cylinder or refill system. Never use reclaimed fluid,
unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid
from a container that has been left open.
Brake Fluid Type DOT 3
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1010
Brake Fluid: Testing and Inspection
Indications of fluid contamination: Swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid.
To test for contamination: Put small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil contamination.
If contaminated: Drain and thoroughly flush system, and replace all rubber parts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1011
Brake Fluid: Service and Repair
Aluminum Master Cylinder
NOTES:
- Check master cylinder fluid level twice annually.
- Master cylinder reservoirs are marked with the words "fill to bottom of rings".
- Add DOT 3 fluid to bring the level to the bottom of the primary split ring.
CAUTION: Use of brake fluid with a lower boiling point than DOT 3 fluid could result in brake failure
during long, hard braking.
CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in
this manner will absorb moisture which could result in brake failure during long, hard braking.
CAUTION: Use of petroleum based fluids will result in seal damage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine - Coolant Recommendations
Coolant: Technical Service Bulletins Engine - Coolant Recommendations
NO: 07-03-97
GROUP: Cooling
DATE: May 9, 1997
SUBJECT: Engine Coolant Usage
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993
TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE
BULLETIN IS REVISED.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1997 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/
Power Ram/Power Ram Cab & Chassis
1989 - 1993 (AG) Daytona
1989 (AH) Lancer/LeBaron GTS
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1997 (AN) Dakota
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 1997 (BR) Ram Truck
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (European Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1989 - 1992 (MJ) Comanche
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1997 (PR) Prowler
1992 - 1997 (SR) Viper/Viper Coupe
1997 (TJ) Wrangler
1989 - 1997 (XJ) Cherokee
1989 - 1995 (YJ) Wrangler
1993 - 1997 (ZJ) Grand Cherokee
DISCUSSION:
Some owners have expressed interest in using engine coolants made with propylene glycol instead
of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals.
Based on recent test data, most owners should not experience significant effects on cooling system
performance when using propylene glycol based coolant. The use of national brand propylene
glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170
(or equivalent ASTM D5216) is acceptable for Chrysler built vehicles.
NOTE:
ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A
SUITABLE ENGINE COOLANT.
However, owners should be discouraged from changing their engine coolant prior to the regularly
scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the
risk of environmental exposure.
Sufficient freeze protection for the region should be maintained. However, do not use more than a
55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a
higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the
temperatures for your region fall below this, use ethylene glycol coolant.
Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in
cooling performance. If this is noticed, the system should be changed back to ethylene glycol
coolant.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine - Coolant Recommendations > Page 1016
The two types of coolant should not be mixed. The standard testers for measuring freeze protection
will not provide an accurate reading when this occurs. If the cooling system is changed to
propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling
system flush procedure. The freeze protection of propylene glycol cannot be measured with a
standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol
is the preferred test tool.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine - Coolant Recommendations > Page 1017
Coolant: Technical Service Bulletins Engine Coolant - Recycling Recommendations
SUBJECT: Engine Coolant Recycling NO.:
07-03-90
GROUP: COOLING
DATE: Dec. 21, 1990
MODELS:
All Domestic & Import Vehicles
DISCUSSION:
A number of systems are being marketed to "recycle" or "reconstitute" used ethylene glycol
antifreeze/coolant in the dealership. Some of the systems have been advertised as producing a
recycled antifreeze "as good as" original and suggest the recycled product is suitable for use in
Chrysler Corporation vehicles.
Tests, so far, indicate most of these systems merely remove suspended solids from the used
antifreeze/coolant through the use of various size filters. These systems do not remove glycol
degradation products, or dissolved solids, which can cause water pump seal wear.
These systems use a universal "reinhibitor package". The "reinhibitor package" can not restore
every type antifreeze/coolant inhibitor system to a like new condition.
Tests results indicate these "recycled" products do not consistently provide the protection required
in Chrysler Corporation engines and cooling systems.
The use of these "reconstituted" antifreeze/coolants is not authorized in the performance of any
repair covered under the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Page 1018
Coolant: Specifications
COOLING SYSTEM CAPACITY
1988-89 Caravan / Voyager / Grand Caravan / Grand Voyager
2.5L Engine .........................................................................................................................................
........................................................ 8.1 L (8.5 qts) 3.0L Engine
without rear heater ...............................................................................................................................
............................................... 9.5 L (10.0 qts) with rear heater ..........................................................
....................................................................................................................... 10.5 L (11.0 qts)
NOTES:
- Includes 0.47 L (1.0 pt) for the heater and coolant reserve bottle.
- Includes 0.95 L (1.0 qt) for rear heater systems, if equipped.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Page 1019
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature
Fluid - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1028
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1029
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1030
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature
Fluid - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page
1036
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page
1037
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page
1038
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Page 1039
Fluid - A/T: Specifications
CAPACITY, Initial Refill*: .....................................................................................................................
....................................................................AP**
All .........................................................................................................................................................
.............................................3.8 Liters 4.0 Quarts
*With the engine at operating temperature, shift transmission through all gears. Check fluid level in
PARK and add fluid as needed **May use AF or MA when AP is not available only for "Topping
off".
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level & Condition Check
Fluid - A/T: Service and Repair Fluid Level & Condition Check
Fluid Level
The transmission and differential sump have a common oil sump with a opening between the two.
The torque converter fills in both the "P" Park and "N" Neutral positions.
Place the selector lever in "P" Park to check fluid level.
The engine should be running at idle speed for at least one minute, with the vehicle on level
ground. This will assure complete oil level stabilization between differential and transmission.
The fluid should be at normal operating temperature (approximately 82 C. or 180 F).
The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator.
Fluid Condition
Along with fluid level, it is important to check the condition of the fluid.
- When the fluid smells burned, and is contaminated with metal or friction material particles, a
complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
- If there is any doubt about its condition, drain out a sample for a double check.
Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt.
Low Fluid Level Symptoms
Low fluid level can cause a variety of conditions because it allows the pump to take in air along with
the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be
low and build up slowly.
Improper Filling Level Symptoms
Improper filling can also raise the fluid level too high.
- When the transaxle has too much fluid, the gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can
interfere with normal valve, clutch and accumulator operation.
Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a
leak.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level & Condition Check > Page 1042
Fluid - A/T: Service and Repair Fluid and Filter Change
Fluid and Filter Change
When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission
Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also
the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is
disassembled for any reason, the fluid and filter should be changed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level & Condition Check > Page 1043
Fluid - A/T: Service and Repair Fluid Drain and Refill
Procedure
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan.
2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan.
3. Install a new filter and O-ring on bottom of the valve body.
4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to
19 Nm (165 in-lbs).
5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill
tube.
6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each position, ending in the park or neutral position.
7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick.
CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil
(100F). Upper holes for hot oil (180F).
8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the
HOT region.
9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill
tube.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications
Fluid - M/T: Specifications
All..........................................................................................................................................................
.........................5W-30 SF/CC, SF/CD, SG/CD, SG
CAPACITY, Refill: 5-speed A525.........................................................................................................
................................................................................2.1 Liters 4.6 Pints
5-speed A520, A555, A569 .................................................................................................................
.................................................2.3 Liters 4.8 Pints
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - New `SG' Level Oil
Engine Oil: Technical Service Bulletins Engine Oil - New `SG' Level Oil
Models
All 1989 And Earlier Domestic & Import Vehicles
Subject
New "SG" Quality Engine Oil
Index
LUBRICATION
Date
April 24, 1989
No.
10-01-89
(C10-01-9) BODY CODE LEGEND
ALL 1989 AND EARLIER CHRYSLER/PLYMOUTH & DODGE DOMESTIC & IMPORT VEHICLES
"SG" QUALITY ENGINE OIL
The quality of engine oil recommended for use in all Chrysler Motors' vehicles has been upgraded
to an "SG" level. The new "SG" quality engine oils can provide significant improvements
concerning sludge, varnish and wear control. These new quality oils may also be used in older
vehicles where lower quality oils (SE, SF, SF/CC) were recommended. Specific recommendations
for all 1989 vehicles may be found in the vehicle "Owners Manual".
The new "SG" engine oils are currently being introduced into the MOPAR product line in addition to
being commercially available through many automotive supply outlets.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Page 1051
Engine Oil: Specifications Oil Capacity
Oil Capacity
Crankcase Only With Filter Change
4.0 Quarts 4.5 Quarts
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > A/C System
Refrigerant: Specifications A/C System
REFRIGERANT CAPACITIES
DODGE/PLYMOUTH TRUCKS
1992 Ram 50 pickup ............................................................................................................................
.............................................. 0.8 kg (30 oz.) Ramcharger ..................................................................
............................................................................................................. 1.3 kg (44 oz.)
1992-91 Dakota ...................................................................................................................................
................................................... 1.2 kg (40 oz.) B-Series van ............................................................
.................................................................................................................. 1.3 kg (44 oz.) with rear
unit .......................................................................................................................................................
...................... 1.8 kg (62 oz.)
1992-90 Caravan, Mini Ram, Voyager
................................................................................................................................................... 0.9 kg
(32 oz.) with rear unit ...........................................................................................................................
.................................................. 1.2 kg (43 oz.)
1992-88 D/W-Series pickup .................................................................................................................
.................................................. 1.3 kg (44 oz.)
1990-87 Dakota ...................................................................................................................................
................................................... 1.3 kg (44 oz.)
1990-83 B-Series van ..........................................................................................................................
.................................................... 1.4 kg (48 oz.) with rear unit ...........................................................
.................................................................................................................. 1.8 kg (62 oz.)
1989-84 Caravan, Mini-Ram, Voyager
................................................................................................................................................... 1.1 kg
(38 oz.) with rear AC ............................................................................................................................
................................................. 1.3 kg (44 oz.)
1987-83 D/W-Series pickup .................................................................................................................
.................................................. 1.1 kg (40 oz.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > A/C System >
Page 1056
Refrigerant: Specifications Capacities
Capacities
Capacity
2.38 lb (US)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > A/C System >
Page 1057
Refrigerant: Specifications Capacities
Capacities
Capacity
2.70 lb (US)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications
Fig. 10 A/C Component Oil Capacity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Oil
Charge Additions
Refrigerant Oil: Service and Repair Oil Charge Additions
If there are no signs of external oil leakage, proceed as follows to add oil to system during
component replacement.
1. Discharge system refer to, Heating and Air Conditioning/Service and Repair and measure
amount of oil collected in discharge container. The amount of oil collected when discharging
system must be replaced with new refrigeration oil to maintain proper oil charge.
2. Remove defective components. Measure amount of oil remaining in compressor, if removed.
3. Add correct amount of oil to components. Refer to Air Conditioning/Specifications/Capacities.
4. Install replacement components, then evacuate and recharge system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Oil
Charge Additions > Page 1063
Refrigerant Oil: Service and Repair Refrigerant Oil Level Check
Compressor oil level need only be checked when there is evidence of oil loss from the system as in
the case of a broken line, leaking fitting or component, defective compressor seal or collision
damage to system. A wet, shiny surface around a leak point is evidence of oil loss.
These compressors must be removed from vehicle and drained to check the oil level, proceed as
follows: 1. Discharge system refer to, DISCHARGING & EVACUATING SYSTEM, and repair leak
as necessary. 2. Disconnect suction and discharge lines from compressor, then remove
compressor and clutch assembly from vehicle. 3. Invert compressor and drain oil through suction
and discharge ports. 4. Determine the correct amount of oil to add to compressor by subtracting the
amount of oil remaining in other components. Refer to . 5. On all models, add oil to compressor
through suction port. 6. Reinstall compressor using new gaskets on refrigerant line fittings, then
evacuate and recharge system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding
Brake Bleeding: Service and Repair About Brake System Bleeding
WHEN BLEEDING BRAKES REMEMBER...
- Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender
covers to protect the vehicle's finish and electrical system.
- Always flush and bleed the brake hydraulic sys. when servicing the brakes, because:
Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake
fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which
may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits
and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of
the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should
be flushed.
- Never reuse brake fluid that has been drained from the brake system.
DOT 3,4 or DOT 5
As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type
fluid.
DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based.
DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a
dye).
DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if
all old fluid isn't removed when a system is refilled with silicone).
Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture
over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic
and won't damage paint like conventional brake fluid. It also has a higher boiling point.
Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve
brake systems in antique vehicles and those that sit for long periods of time between use.
Silicone also has slightly different physical properties and compressibility, making it unsuitable for
ABS systems calibrated to work with DOT 3 or 4 brake fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake
System Bleeding > Page 1068
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
When bleeding ABS systems use only diaphragm type bleed pressure bleeder.
1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to
de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a
suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a
glass container partially filled with
clean brake fluid.
4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until
clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order.
6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure
bleeder from vehicle, ensure proper fluid level in master cylinder.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag System Arming and Disarming
1. Place ignition switch in lock position.
2. Disconnect and tape battery ground cable connector.
3. Wait at least 1 minute after disconnecting battery ground cable before performing any further
repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a
short time even after battery has been disconnected.
4. After repairs are performed, connect battery ground cable.
5. From passenger side of vehicle, turn ignition switch to On position.
6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to
indicate if SRS system is functioning correctly.
7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Locations
Circuit Breaker: Locations
Circuit Location Amp
Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats &
Mirror.........Fuse Block...........30
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions
Circuit Breaker: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1078
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1079
Circuit Breaker: Electrical Diagrams
Circuit Location Amp
Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats &
Mirror.........Fuse Block...........30
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Page 1080
Circuit Breaker: Testing and Inspection
NOTE: Perform SWITCH VOLTAGE TEST, and verify that the battery is fully charged before
starting this test.
1. Locate the circuit breaker (in the fuse box) and connect the positive lead of a voltmeter to the
light green terminal. Connect the other lead of the voltmeter to a good ground and check that there
is battery voltage.
2. If battery voltage is not present, connect the voltmeter to the other (battery) side of the circuit
breaker and check for battery voltage.
3. If battery voltage is present, the circuit breaker is defective and needs to be replaced. If battery
voltage is not present, check for an open wire in the harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Locations
Fuse Block: Locations
Lower I/P Components
RH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1086
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1087
Fuse Block: Connector Views
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1088
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1089
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1090
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1091
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1092
Fuse Block: Electrical Diagrams
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1093
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1094
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1095
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1096
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1097
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component
Information > Locations
Emissions Maintenance Light: Locations
Upper I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component
Information > Locations > Page 1102
Emissions Maintenance Light: Service and Repair
Refer to Powertrain Management/Emission Control Systems/Service and Repair for reset
procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
On-Board Diagnosis Connector Location
On-Board Diagnosis Connector Location
On-Board Diagnosis Connector Location
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation > Page 1106
On-Board Diagnosis Connector Location
On-Board Diagnosis Connector Location
This reminder system uses ignition on time to calculate maintenance intervals. After necessary
emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the
on-board diagnostic connector. Follow instructions indicated by DRB II tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation > Page 1107
Maintenance Required Lamp/Indicator: Service and Repair
On-Board Diagnosis Connector Location
On certain models, this Emission Maintenance Reminder System is incorporated into the engine
controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000,
82,500 or 120,000 miles it will illuminate the EMR lamp. When the indicated mileage is reached or
the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset.
1. At 60,00 miles, proceed as follows:
a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve.
2. At 82,500 miles, proceed as follows:
a. Replace oxygen sensor.
3. At 120,000 miles, proceed as follows:
a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve.
4. On 1990-95 models, after necessary emission maintenance has been performed, connect
Diagnosis Read-Out Box II (DRB II) to the on-board
diagnosis connector. See images above.
5. On all models, Follow instructions indicated by DRB II tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Malfunction
Indicator Lamp Driver Module > Component Information > Locations
Malfunction Indicator Lamp Driver Module: Locations
Upper I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear
Tires: Customer Interest Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 1121
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 1122
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear
Tires: All Technical Service Bulletins Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear >
Page 1128
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear >
Page 1129
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
Wheel Bearing: Specifications Nut Torque
Nut Torque
Front Axle Nut Torque 180 ft.lb
Rear Bearing Nut Torque 270 in.lb
+/- 30 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
> Page 1133
Wheel Bearing: Adjustments
Fig. 3 Wheel bearing assembly
1. Raise and support rear of vehicle.
2. Tighten adjusting nut to 27 to 34nm (240 to 300 in. lbs.) while rotating wheel.
3. Stop wheel and loosen adjusting nut.
4. Tighten adjusting nut finger tight. End play should be 0.0001-0.0020 inch.
5. Install castle lock with slots aligned with cotter pin hole.
6. Install cotter pin and grease cap.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front
Wheel Bearing: Service and Repair Front
Permanent Bearings
REMOVAL
Fig. 15 Removing hub & bearing assembly
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and drive shaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and
washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6.
Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the
caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor,
then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV
joint during this procedure.
Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported.
9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as
shown.
10. Remove hub and bearing assembly.
INSTALLATION
Fig. 16 Seal installation
1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using
oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of
seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse
driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve
using a suitable lubricant.
4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint
stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install
tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install
rotor, then position caliper over rotor and guide hold-down spring below machined guides on
knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut,
then with brakes applied, tighten nut to specifications.
10. Install spring washer, locknut and cotter pin.
Replaceable Bearings
REMOVAL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1136
Fig. 14 Hub removal
Fig. 12 Removing bearing from knuckle
1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or
equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer.
4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle
using tool No. C-4811-2 or equivalent.
INSTALLATION
Fig. 13 Installing bearing into knuckle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1137
Fig. 14 Installing hub into knuckle
1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer.
Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No.
C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No.
C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1138
Wheel Bearing: Service and Repair Rear
REMOVAL
1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Remove cotter pin, nut
lock, spring washer and hub nut. 3. Remove half shaft flange retaining bolts. 4. Half shaft is spring
loaded, compress inner half shaft joint slightly pulling down to clear rear carrier output shaft. 5.
Remove half shaft by pulling half shaft assembly inboard. 6. Remove wheel bearing mounting
bolts, then wheel bearing and hub assembly. 7. Replace grease seal if needed.
INSTALLATION
1. If grease seal was removed, install a new seal using installer tool No. 6536-A or equivalent.
Lubricate circumference of seal before installation. 2. Install washer and hub nut. With brakes
applied, torque to 180 ft. lbs. 3. Install spring washer, nut lock and cotter pin. 4. Install hub and
bearing assembly. Torque bolts in a crossing pattern to 96 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Permanent Bearings
Wheel Hub: Service and Repair Permanent Bearings
REMOVAL
Fig. 15 Removing hub & bearing assembly
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and drive shaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and
washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6.
Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the
caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor,
then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV
joint during this procedure.
Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported.
9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as
shown.
10. Remove hub and bearing assembly.
INSTALLATION
Fig. 16 Seal installation
1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using
oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of
seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse
driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve
using a suitable lubricant.
4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint
stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install
tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install
rotor, then position caliper over rotor and guide hold-down spring below machined guides on
knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut,
then with brakes applied, tighten nut to specifications.
10. Install spring washer, locknut and cotter pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Permanent Bearings > Page 1143
Wheel Hub: Service and Repair Replaceable Bearings
REMOVAL
Fig. 14 Hub removal
Fig. 12 Removing bearing from knuckle
1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or
equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer.
4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle
using tool No. C-4811-2 or equivalent.
INSTALLATION
Fig. 13 Installing bearing into knuckle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair
> Permanent Bearings > Page 1144
Fig. 14 Installing hub into knuckle
1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer.
Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No.
C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No.
C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
Wheel Lug Nuts 95 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
SERVICE SPECIFICATIONS
Compression pressure .....................................................................................................................
840 kPa (178 psi) +/- 100 kPa (14 psi) @ 250-400 rpm Maximum variation .......................................
..............................................................................................................................................................
.... 25% Manifold vacuum ....................................................................................................................
........................................................... 520 mmHg (20 in.Hg.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1153
Compression Check: Testing and Inspection
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the
throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure
gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the
compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
NOTE: Correct engine compression pressures should be 178 psi +/- 14 psi, Maximum cylinder
deviation 25%
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications
Camshaft: Specifications
CAMSHAFT
Cam height: Intake ..............................................................................................................................
.................................................................... 41.25 mm (1.6240 in.)
Limit .....................................................................................................................................................
.......................................... 40.75 mm (1.6043 in.)
Exhaust ................................................................................................................................................
............................................... 41.25 mm (1.6240 in.)
Limit .....................................................................................................................................................
.......................................... 40.75 mm (1.6043 in.)
Journal O.D. ........................................................................................................................................
........................................................ 34 mm (1.34 in.)
Bearing oil clearance
.......................................................................................................................................................
0.05 - 0.09 mm (.0020 - .0035 in.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications > Page 1158
Camshaft: Service and Repair
Fig. 1 Cylinder Head-Camshaft-Valves
Fig. 2 Rocker Cover
REMOVE VALVE COVERS
1. Remove air cleaner assembly. 2. Disconnect battery and relocate spark plug wires. 3. Remove
vacuum connections. 4. Remove rocker cover screws and remove cover.
REMOVE CAMSHAFT SPROCKETS
Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove
camshaft sprockets. See: Timing Components/Timing Belt/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications > Page 1159
Fig. 3 Auto Lash Adjuster Check
CHECK AUTO LASH ADJUSTER FUNCTION
Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker
arm and VERY LIGHTLY push the auto adjuster ball check down. While lightly holding the check
ball down move the rocker up and down to check for free play. If there is no play replace the
adjuster.
NOTE: Do not disassemble the auto lash adjuster.
Fig. 4 Auto Lash Adjuster Retainers
REMOVE CAMSHAFTS
1. Install auto lash adjuster retainers.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications > Page 1160
Fig. 11 Distributor Drive
2. Remove distributor extension. 3. When removing camshaft bearing caps do not remove the bolts
from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an
assembly.
Fig. 5 Check Camshafts
INSPECT CAMSHAFTS
1. Inspect camshaft bearing journals for damage and binding. If journals are binding, also check the
cylinder head for damage Fig. 1. Also check
cylinder head oil holes for clogging.
2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the
camshaft and replace if abnormal wear is evident. 3. Check the cam surface for abnormal wear and
damage and replace if defective. Also measure the cam height Fig. 5.and replace if out of limit,
standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch.
Fig. 6 Inspect Rocker Arms
INSPECT ROCKER ARMS
Check rocker arms for wear or damage. Replace as necessary.
INSPECT ROCKER ARM SHAFTS
Fig. 7 Rocker Arm Shaft Identification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications > Page 1161
NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on
the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does
not have this oil passage.
1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily
damaged or worn. 2. Check oil holes for clogging with small wire, clean as required.
INSTALL CAMSHAFTS
Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head.
Fig. 8 Camshaft Bearing Caps Position
REASSEMBLE ROCKER ARMS
1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown.
and in numerical order.
Fig. 9 Number One Camshaft Bearing Cap
NOTE: Identify number one bearing cap number one and number four caps are similar.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications > Page 1162
Fig. 10 Assemble Rocker Arm And Shafts
2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs.
9 and 10 note that the machined portion of the
rocker shaft is facing down.
3. Insert attaching bolts to retain assembly.
INSTALL ROCKER ARM SHAFT ASSEMBLY
1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in. 2. Install the
rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark
on the cylinder head are in the same
direction.
NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other.
3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and #
4. 4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs.
Fig. 11 Distributor Drive
5. Install distributor drive adaptor assembly Fig. 11.
INSTALL VALVE COVERS
1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. See Fig. 2 and apply
sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. 3. Install cover and
tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications
ROCKER ARM
Rocker arm I.D. ...................................................................................................................................
.......................................................... 19 mm (.75 in.)
Clearance (Rocker arm to shaft)
.......................................................................................................................................... 0.01-0.04
mm (.0004-.0016 in.)
Limit .....................................................................................................................................................
............................................... 0.10 mm (0039 in.)
Rocker arm shaft O.D. .........................................................................................................................
..................................................... 18.9 mm (.744 in.)
Rocker arm shaft spring free length:
Intake ...................................................................................................................................................
............................................... 55.2 mm (2.173 in.)
Exhaust ................................................................................................................................................
............................................... 55.2 mm (2.173 in.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1166
Rocker Arm Assembly: Service and Repair
Fig. 1 Cylinder Head-Camshaft-Valves
Fig. 2 Rocker Cover
REMOVE VALVE COVERS
1. Remove air cleaner assembly. 2. Disconnect battery and relocate spark plug wires. 3. Remove
vacuum connections. 4. Remove rocker cover screws and remove cover.
REMOVE CAMSHAFT SPROCKETS
Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove
camshaft sprockets. See: Timing Components/Timing Belt/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1167
Fig. 3 Auto Lash Adjuster Check
CHECK AUTO LASH ADJUSTER FUNCTION
Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker
arm and VERY LIGHTLY push the auto adjuster ball check down. While lightly holding the check
ball down move the rocker up and down to check for free play. If there is no play replace the
adjuster.
NOTE: Do not disassemble the auto lash adjuster.
Fig. 4 Auto Lash Adjuster Retainers
REMOVE CAMSHAFTS
1. Install auto lash adjuster retainers.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1168
Fig. 11 Distributor Drive
2. Remove distributor extension. 3. When removing camshaft bearing caps do not remove the bolts
from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an
assembly.
Fig. 5 Check Camshafts
INSPECT CAMSHAFTS
1. Inspect camshaft bearing journals for damage and binding. If journals are binding, also check the
cylinder head for damage Fig. 1. Also check
cylinder head oil holes for clogging.
2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the
camshaft and replace if abnormal wear is evident. 3. Check the cam surface for abnormal wear and
damage and replace if defective. Also measure the cam height Fig. 5.and replace if out of limit,
standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch.
Fig. 6 Inspect Rocker Arms
INSPECT ROCKER ARMS
Check rocker arms for wear or damage. Replace as necessary.
INSPECT ROCKER ARM SHAFTS
Fig. 7 Rocker Arm Shaft Identification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1169
NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on
the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does
not have this oil passage.
1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily
damaged or worn. 2. Check oil holes for clogging with small wire, clean as required.
INSTALL CAMSHAFTS
Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head.
Fig. 8 Camshaft Bearing Caps Position
REASSEMBLE ROCKER ARMS
1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown.
and in numerical order.
Fig. 9 Number One Camshaft Bearing Cap
NOTE: Identify number one bearing cap number one and number four caps are similar.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1170
Fig. 10 Assemble Rocker Arm And Shafts
2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs.
9 and 10 note that the machined portion of the
rocker shaft is facing down.
3. Insert attaching bolts to retain assembly.
INSTALL ROCKER ARM SHAFT ASSEMBLY
1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in. 2. Install the
rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark
on the cylinder head are in the same
direction.
NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other.
3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and #
4. 4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs.
Fig. 11 Distributor Drive
5. Install distributor drive adaptor assembly Fig. 11.
INSTALL VALVE COVERS
1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. See Fig. 2 and apply
sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. 3. Install cover and
tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Specifications
Connecting Rod Bearing: Specifications
CONNECTING ROD
Length Center to Center
............................................................................................................................................... 140.9 141.0 mm (5.547 - 5.551 in.)
Bend ....................................................................................................................................................
........................................ 0.05 mm (.0020 in.) or less
Twist ....................................................................................................................................................
........................................... 0.1 mm (.004 in.) or less
Connecting rod side clearance
....................................................................................................................................................
0.10-0.25( .0039-.0098 in.)
Limit .....................................................................................................................................................
.................................................. 0.4 mm (.016 in.)
Piston pin press-in load
...................................................................................................................................................
7,500-17,500 N (1,686-3,934 lbs.)
CONNECTING ROD BEARING
Oil clearance ........................................................................................................................................
............................. 0.016-0.046 mm (.0006.0018 in.)
Limit .....................................................................................................................................................
.................................................. 0.1 mm (.004 in.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Connecting Rod Cap Bolts/Nuts
Connecting Rod: Specifications
Connecting Rod Nuts 38 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1179
Connecting Rod: Specifications Connecting Rod Specifications
CONNECTING ROD
Length Center to Center
............................................................................................................................................... 140.9 141.0 mm (5.547 - 5.551 in.)
Bend ....................................................................................................................................................
........................................ 0.05 mm (.0020 in.) or less
Twist ....................................................................................................................................................
........................................... 0.1 mm (.004 in.) or less
Connecting rod side clearance
....................................................................................................................................................
0.10-0.25( .0039-.0098 in.)
Limit .....................................................................................................................................................
.................................................. 0.4 mm (.016 in.)
Piston pin press-in load
...................................................................................................................................................
7,500-17,500 N (1,686-3,934 lbs.)
CONNECTING ROD BEARING
Oil clearance ........................................................................................................................................
............................. 0.016-0.046 mm (.0006.0018 in.)
Limit .....................................................................................................................................................
.................................................. 0.1 mm (.004 in.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Page 1180
Connecting Rod: Service and Repair
Fig. 16 Piston & rod installation
The piston and rod is assembled with front mark facing toward front of engine (toward timing belt),
Fig. 16. Connecting rod front mark (72), must always face forward (toward timing belt), Fig. 16.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Specifications
Crankshaft Main Bearing: Specifications
CRANKSHAFT MAIN BEARINGS
Oil clearance ........................................................................................................................................
.............................. 0.02-0.048 mm (.0008-.0019 in.)
Limit .....................................................................................................................................................
.................................................. 0.1 mm (.004 in.)
CRANKSHAFT
Pin O.D. ...............................................................................................................................................
........................ 49.980 - 50.0 mm (1.968 - 1.969 in.)
Journal O.D. ........................................................................................................................................
......................... 59.980 - 60.0 mm (2.361 - 2.362 in.)
Out-of-roundness of journal and pin
....................................................................................................................................... Less than
0.03 mm (.0012 in.)
Taper of journal and pin
.......................................................................................................................................................
Less than 0.005 mm (.0002 in.)
End play ...............................................................................................................................................
................................ 0.05-0.25 mm (.0020-.0098 in.)
Limit .....................................................................................................................................................
................................................... 0.3 mm (012 in.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Technical Service Bulletins > Engine - Crankshaft Identification
Crankshaft: Technical Service Bulletins Engine - Crankshaft Identification
NO: 09-20-95
GROUP: Engine
DATE: Dec. 8, 1995
SUBJECT: 2.5L/3.0L MMC Engine Crankshaft Identification
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/Lebaron Sedan
1988 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible
1992 - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
1987 - 1995 (AS) Caravan/Voyager/Town & Country
1995 - 1996 (FJ) Avenger/Sebring
1995 - 1996 (JA) Breeze/Cirrus/Stratus
1996 (JX) Sebring Convertible
1996 (NS) Caravan/Voyager
NOTE:
This bulletin applies to vehicles equipped with a 2.5L or 3.0L MMC engine.
DISCUSSION:
Service replacement crankshaft main journal and connecting rod journal size identification marks
have changed effective with crankshafts manufactured after August, 1995. The marks have
changed from paint at each position to stamped marks located near the center counterweight as
shown.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Rebuild Specifications
Crankshaft: Specifications Rebuild Specifications
CRANKSHAFT MAIN BEARINGS
Oil clearance ........................................................................................................................................
.............................. 0.02-0.048 mm (.0008-.0019 in.)
Limit .....................................................................................................................................................
.................................................. 0.1 mm (.004 in.)
CRANKSHAFT
Pin O.D. ...............................................................................................................................................
........................ 49.980 - 50.0 mm (1.968 - 1.969 in.)
Journal O.D. ........................................................................................................................................
......................... 59.980 - 60.0 mm (2.361 - 2.362 in.)
Out-of-roundness of journal and pin
....................................................................................................................................... Less than
0.03 mm (.0012 in.)
Taper of journal and pin
.......................................................................................................................................................
Less than 0.005 mm (.0002 in.)
End play ...............................................................................................................................................
................................ 0.05-0.25 mm (.0020-.0098 in.)
Limit .....................................................................................................................................................
................................................... 0.3 mm (012 in.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Rebuild Specifications > Page 1190
Crankshaft: Specifications
Crankshaft Main Bearing Caps 60 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
PISTONS
O.D. .....................................................................................................................................................
................................................... 91.1 mm (3.587 in.)
Clearance ............................................................................................................................................
............................. 0.02 - 0.04 mm (.0008 - .0016 in.)
Ring groove width No. 1 ......................................................................................................................
.............................................................. 1.51 - 1.53 mm (.0594.0602 in.)
No.2 .....................................................................................................................................................
................................. 1.51-1.53 mm (.0594-0602 in.)
Oil ........................................................................................................................................................
............................ 4.010-4.035 mm (.1579-.1589 in.)
Service sizes .......................................................................................................................................
............................................................ 0.25 mm (.010 in.) Oversize ...................................................
................................................................................................................................................ 0.50
mm (.020 in.) Oversize ........................................................................................................................
............................................................................. 0.75 mm (.30 in.) Oversize ....................................
..............................................................................................................................................................
. 1.00 mm (.039 in.) Oversize
PISTON RINGS
Side clearance No. 1 ...........................................................................................................................
......................................................... 0.03-0.09 mm (.0012-.0035 in.)
Limit .....................................................................................................................................................
.................................................. 0.1 mm (.004 in.)
No. 2 ....................................................................................................................................................
................................ 0.02-0.06 mm (.0008-.0024 in.)
Limit .....................................................................................................................................................
.................................................. 0.1 mm (.004 in.)
End gap No. 1 ......................................................................................................................................
.............................................. 0.30-0.45 mm (.0118-.0177 in.)
Limit .....................................................................................................................................................
................................................... 0.8 mm (031 in.)
No. 2 ....................................................................................................................................................
................................ 0.25-0.40 mm (.0098-.0157 in.)
Limit .....................................................................................................................................................
................................................... 0.8 mm (031 in.)
Oil ring side rail ....................................................................................................................................
........................... 0.20 - 0.70 mm (.0079 - .0276 in.)
Limit .....................................................................................................................................................
.................................................. 1.0 mm (.039 in.)
Service sizes .......................................................................................................................................
............................................................ 0.25 mm (.010 in.) Oversize ...................................................
................................................................................................................................................ 0.50
mm (.020 in.) Oversize ........................................................................................................................
........................................................................... 0.75 mm (.030 in.) Oversize ....................................
..............................................................................................................................................................
. 1.00 mm (.039 in.) Oversize
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 1194
Piston: Service and Repair
Fig. 16 Piston & rod installation
The piston and rod is assembled with front mark facing toward front of engine (toward timing belt),
Fig. 16. Connecting rod front mark (72), must always face forward (toward timing belt), Fig. 16.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
PISTONS
O.D. .....................................................................................................................................................
................................................... 91.1 mm (3.587 in.)
Clearance ............................................................................................................................................
............................. 0.02 - 0.04 mm (.0008 - .0016 in.)
Ring groove width No. 1 ......................................................................................................................
.............................................................. 1.51 - 1.53 mm (.0594.0602 in.)
No.2 .....................................................................................................................................................
................................. 1.51-1.53 mm (.0594-0602 in.)
Oil ........................................................................................................................................................
............................ 4.010-4.035 mm (.1579-.1589 in.)
Service sizes .......................................................................................................................................
............................................................ 0.25 mm (.010 in.) Oversize ...................................................
................................................................................................................................................ 0.50
mm (.020 in.) Oversize ........................................................................................................................
............................................................................. 0.75 mm (.30 in.) Oversize ....................................
..............................................................................................................................................................
. 1.00 mm (.039 in.) Oversize
PISTON RINGS
Side clearance No. 1 ...........................................................................................................................
......................................................... 0.03-0.09 mm (.0012-.0035 in.)
Limit .....................................................................................................................................................
.................................................. 0.1 mm (.004 in.)
No. 2 ....................................................................................................................................................
................................ 0.02-0.06 mm (.0008-.0024 in.)
Limit .....................................................................................................................................................
.................................................. 0.1 mm (.004 in.)
End gap No. 1 ......................................................................................................................................
.............................................. 0.30-0.45 mm (.0118-.0177 in.)
Limit .....................................................................................................................................................
................................................... 0.8 mm (031 in.)
No. 2 ....................................................................................................................................................
................................ 0.25-0.40 mm (.0098-.0157 in.)
Limit .....................................................................................................................................................
................................................... 0.8 mm (031 in.)
Oil ring side rail ....................................................................................................................................
........................... 0.20 - 0.70 mm (.0079 - .0276 in.)
Limit .....................................................................................................................................................
.................................................. 1.0 mm (.039 in.)
Service sizes .......................................................................................................................................
............................................................ 0.25 mm (.010 in.) Oversize ...................................................
................................................................................................................................................ 0.50
mm (.020 in.) Oversize ........................................................................................................................
........................................................................... 0.75 mm (.030 in.) Oversize ....................................
..............................................................................................................................................................
. 1.00 mm (.039 in.) Oversize
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications > Page 1198
Piston Ring: Service and Repair
Fig. 17 Installing piston rings
Fig. 18 Positioning ring end gaps
Install piston rings as shown in Figs. 17 and 18.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all
times.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications > Page 1203
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters. No provision for adjustment is provided.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair
Fuel Pressure Release: Service and Repair
1. Loosen gas cap and allow tank pressure to release.
2. Remove wiring harness connector from any injector, then ground one injector terminal.
3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery
for approximately 10 seconds and release system pressure.
4. Remove jumper wires and service fuel system as required.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications
Rocker Arm Assembly: Specifications
ROCKER ARM
Rocker arm I.D. ...................................................................................................................................
.......................................................... 19 mm (.75 in.)
Clearance (Rocker arm to shaft)
.......................................................................................................................................... 0.01-0.04
mm (.0004-.0016 in.)
Limit .....................................................................................................................................................
............................................... 0.10 mm (0039 in.)
Rocker arm shaft O.D. .........................................................................................................................
..................................................... 18.9 mm (.744 in.)
Rocker arm shaft spring free length:
Intake ...................................................................................................................................................
............................................... 55.2 mm (2.173 in.)
Exhaust ................................................................................................................................................
............................................... 55.2 mm (2.173 in.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1210
Rocker Arm Assembly: Service and Repair
Fig. 1 Cylinder Head-Camshaft-Valves
Fig. 2 Rocker Cover
REMOVE VALVE COVERS
1. Remove air cleaner assembly. 2. Disconnect battery and relocate spark plug wires. 3. Remove
vacuum connections. 4. Remove rocker cover screws and remove cover.
REMOVE CAMSHAFT SPROCKETS
Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove
camshaft sprockets. See: Timing Components/Timing Belt/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1211
Fig. 3 Auto Lash Adjuster Check
CHECK AUTO LASH ADJUSTER FUNCTION
Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker
arm and VERY LIGHTLY push the auto adjuster ball check down. While lightly holding the check
ball down move the rocker up and down to check for free play. If there is no play replace the
adjuster.
NOTE: Do not disassemble the auto lash adjuster.
Fig. 4 Auto Lash Adjuster Retainers
REMOVE CAMSHAFTS
1. Install auto lash adjuster retainers.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1212
Fig. 11 Distributor Drive
2. Remove distributor extension. 3. When removing camshaft bearing caps do not remove the bolts
from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an
assembly.
Fig. 5 Check Camshafts
INSPECT CAMSHAFTS
1. Inspect camshaft bearing journals for damage and binding. If journals are binding, also check the
cylinder head for damage Fig. 1. Also check
cylinder head oil holes for clogging.
2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the
camshaft and replace if abnormal wear is evident. 3. Check the cam surface for abnormal wear and
damage and replace if defective. Also measure the cam height Fig. 5.and replace if out of limit,
standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch.
Fig. 6 Inspect Rocker Arms
INSPECT ROCKER ARMS
Check rocker arms for wear or damage. Replace as necessary.
INSPECT ROCKER ARM SHAFTS
Fig. 7 Rocker Arm Shaft Identification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1213
NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on
the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does
not have this oil passage.
1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily
damaged or worn. 2. Check oil holes for clogging with small wire, clean as required.
INSTALL CAMSHAFTS
Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head.
Fig. 8 Camshaft Bearing Caps Position
REASSEMBLE ROCKER ARMS
1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown.
and in numerical order.
Fig. 9 Number One Camshaft Bearing Cap
NOTE: Identify number one bearing cap number one and number four caps are similar.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1214
Fig. 10 Assemble Rocker Arm And Shafts
2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs.
9 and 10 note that the machined portion of the
rocker shaft is facing down.
3. Insert attaching bolts to retain assembly.
INSTALL ROCKER ARM SHAFT ASSEMBLY
1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in. 2. Install the
rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark
on the cylinder head are in the same
direction.
NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other.
3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and #
4. 4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs.
Fig. 11 Distributor Drive
5. Install distributor drive adaptor assembly Fig. 11.
INSTALL VALVE COVERS
1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. See Fig. 2 and apply
sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. 3. Install cover and
tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve
Cover Gasket > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover Gasket: >
091689 > Oct > 89 > Engine - Oil Consumption
Valve Cover Gasket: Customer Interest Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve
Cover Gasket > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover Gasket: >
091689 > Oct > 89 > Engine - Oil Consumption > Page 1224
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve
Cover Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover
Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption
Valve Cover Gasket: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve
Cover Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover
Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 1230
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine
- Smoky Exhaust/Oil Consumption
Technical Service Bulletin # 091892A Date: 930113
Engine - Smoky Exhaust/Oil Consumption
NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993
SUBJECT: Excessive Oil Consumption 3.0L MMC Engine
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD
BE REMOVED FROM YOUR FILES.
MODELS: 1989 - 1993
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau
1990 - 1993 (AG) Daytona
1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible
1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance
1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1990 - 1991 (AQ) Chrysler TC
1988 (C) Dynasty/New Yorker
DISCUSSION:
Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve
guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve
stem seals in addition to the snap rings on the exhaust valve guides. The build code label is
located on the intake plenum.
SYMPTOM/CONDITION:
Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake
manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles
with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than
50,000 miles.
DIAGNOSIS:
Verify the PCV system is functioning properly and engine compression is within specifications.
Refer to the appropriate technical service manual for test procedures and specifications. If the PCV
system and engine compression are within specification, perform the repair procedure.
PARTS REQUIRED:
SPECIAL TOOLS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve
stem seals or cylinder head replacement as determined by inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine
- Smoky Exhaust/Oil Consumption > Page 1239
1. Remove the intake plenum and manifold.
2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank
using the procedure in the appropriate technical service manual.
3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will
prevent the cam from possibly coming out of the journals when the engine is rotated later.
4. Check front bank cylinders in # 4, # 2, then # 6 sequence.
NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE
CYLINDER HEAD.
5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use
special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer,
valve spring and valve spring seat.
6. Remove the valve stem seals.
7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790),
measure the distance between the top of the exhaust valve guide and the top of the valve guide
boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less
the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is
.335" (8.5 mm) or more, perform PROCEDURE A.
8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence.
Procedure A
PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle)
1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide
(refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine
- Smoky Exhaust/Oil Consumption > Page 1240
2. Using a magnet and shop towel, remove the cuttings from the cylinder head.
3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4).
4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
5. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step
4 of PROCEDURE A.
7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all
exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head.
8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs.
Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads.
9. Using the procedures in the appropriate service manual, reassemble the engine.
Procedure B
PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation
1. Remove the cylinder head using the procedure in the appropriate service manual.
2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned
to their original position at reassembly.
3. Remove all of the valve stem seals.
4. Check the height on any exhaust valve guides not already checked to determine if height
correction will be required on more than one guide.
5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height
corrected, especially the face that special tool MD998115 will contact.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine
- Smoky Exhaust/Oil Consumption > Page 1241
6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the
combustion chamber side to provide a valve guide height from the top of the guide to the top of the
boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the
height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1
and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5
mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until
the .453" (11.5 mm) height is achieved.
7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual.
8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve
guides (refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings.
10. Install a snap ring on each exhaust valve guide (refer to fig. 4).
11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
12. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
13. Reassemble the cylinder head and install using the procedure in the appropriate service
manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to
both heads.
14. Using the procedures in the appropriate service manual, reassemble the engine.
POLICY: Reimbursable within the provisions of the warranty.
Labor Operation
TIME ALLOWANCE: Labor Operation No.
09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs.
Seals, Both Heads on Vehicle
09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs.
Remove Front Head and repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine
- Smoky Exhaust/Oil Consumption > Page 1242
or Replace Head as Required
09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs.
Remove Rear Head and Repair or Replace Head as Required
09-35-01-95 Remove Both Heads and Repair 6.4 Hrs.
or Replace Head as Required
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan >
93 > Engine - Smoky Exhaust/Oil Consumption
Technical Service Bulletin # 091892A Date: 930113
Engine - Smoky Exhaust/Oil Consumption
NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993
SUBJECT: Excessive Oil Consumption 3.0L MMC Engine
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD
BE REMOVED FROM YOUR FILES.
MODELS: 1989 - 1993
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau
1990 - 1993 (AG) Daytona
1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible
1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance
1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1990 - 1991 (AQ) Chrysler TC
1988 (C) Dynasty/New Yorker
DISCUSSION:
Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve
guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve
stem seals in addition to the snap rings on the exhaust valve guides. The build code label is
located on the intake plenum.
SYMPTOM/CONDITION:
Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake
manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles
with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than
50,000 miles.
DIAGNOSIS:
Verify the PCV system is functioning properly and engine compression is within specifications.
Refer to the appropriate technical service manual for test procedures and specifications. If the PCV
system and engine compression are within specification, perform the repair procedure.
PARTS REQUIRED:
SPECIAL TOOLS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve
stem seals or cylinder head replacement as determined by inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan >
93 > Engine - Smoky Exhaust/Oil Consumption > Page 1248
1. Remove the intake plenum and manifold.
2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank
using the procedure in the appropriate technical service manual.
3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will
prevent the cam from possibly coming out of the journals when the engine is rotated later.
4. Check front bank cylinders in # 4, # 2, then # 6 sequence.
NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE
CYLINDER HEAD.
5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use
special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer,
valve spring and valve spring seat.
6. Remove the valve stem seals.
7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790),
measure the distance between the top of the exhaust valve guide and the top of the valve guide
boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less
the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is
.335" (8.5 mm) or more, perform PROCEDURE A.
8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence.
Procedure A
PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle)
1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide
(refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan >
93 > Engine - Smoky Exhaust/Oil Consumption > Page 1249
2. Using a magnet and shop towel, remove the cuttings from the cylinder head.
3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4).
4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
5. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step
4 of PROCEDURE A.
7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all
exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head.
8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs.
Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads.
9. Using the procedures in the appropriate service manual, reassemble the engine.
Procedure B
PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation
1. Remove the cylinder head using the procedure in the appropriate service manual.
2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned
to their original position at reassembly.
3. Remove all of the valve stem seals.
4. Check the height on any exhaust valve guides not already checked to determine if height
correction will be required on more than one guide.
5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height
corrected, especially the face that special tool MD998115 will contact.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan >
93 > Engine - Smoky Exhaust/Oil Consumption > Page 1250
6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the
combustion chamber side to provide a valve guide height from the top of the guide to the top of the
boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the
height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1
and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5
mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until
the .453" (11.5 mm) height is achieved.
7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual.
8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve
guides (refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings.
10. Install a snap ring on each exhaust valve guide (refer to fig. 4).
11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
12. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
13. Reassemble the cylinder head and install using the procedure in the appropriate service
manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to
both heads.
14. Using the procedures in the appropriate service manual, reassemble the engine.
POLICY: Reimbursable within the provisions of the warranty.
Labor Operation
TIME ALLOWANCE: Labor Operation No.
09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs.
Seals, Both Heads on Vehicle
09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs.
Remove Front Head and repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan >
93 > Engine - Smoky Exhaust/Oil Consumption > Page 1251
or Replace Head as Required
09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs.
Remove Rear Head and Repair or Replace Head as Required
09-35-01-95 Remove Both Heads and Repair 6.4 Hrs.
or Replace Head as Required
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Specifications
Valve Spring: Specifications
Free length ..........................................................................................................................................
......................................................... 1.995 - 1.998 in. Maximum straightness deviation ....................
..............................................................................................................................................................
..... 4 °
Installed height ....................................................................................................................................
..................................................................... 1.590 in. Pressure Closed .............................................
........................................................................................................................................... 73 lbs. @
1.590 in.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > Customer Interest for Valve: > 18-05-97 > Feb > 97 > Engine Driveway Die Out/Rough Idle/Low Power
Valve: Customer Interest Engine - Driveway Die Out/Rough Idle/Low Power
NO: 18-05-97
GROUP: Vehicle Performance
DATE: Feb. 14, 1997
SUBJECT: Intake Valve Deposits
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-16-93, DATED NOV. 12,
1993 AND 18-20-94, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR
FILES AND NOTED IN THE 1993 AND 1994 TECHNICAL SERVICE BULLETIN MANUALS
(PUBLICATION NO's. 81-699-94000 AND 81-699-95054). ALL REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS** AND INCLUDE MODEL AND APPLICATION CHANGES.
MODELS:
**1989 - 1995** (AA) Spirit/Acclaim/LeBaron Sedan
**1988 - 1993** (AC) Dynasty/New Yorker Salon
**1990 - 1994** (AG) Daytona
**1990 - 1995** (AJ) LeBaron Coupe/LeBaron Convertible
**1992 - 1994** (AP) Shadow/Shadow Convertible/Sundance
**1987 - 1995** (AS) Town & Country/Caravan/Voyager
**1996 - 1997** (NS) Town & Country/Caravan/Voyager
**NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L ENGINE.**
SYMPTOM/CONDITION:
Driveway die out, rough idle, lack of power, sags, and hesitation.
DISCUSSION:
The above conditions may be the result of a build up of deposits on the back of the intake valves
causing blockage of fuel delivery into the upper combustion chamber. This blockage results in fuel
starvation. The deposits can be the result of fuel blending methods that have insufficient or
ineffective fuel detergent additives.
Fuel quality is a direct result of the crude oil used, the refinement process, the storage, delivery and
distribution methods, and the blending of additive compounds. Using fuel with a higher posted
octane number does not guarantee high quality, or that it is blended with adequate or effective
detergent, corrosion inhibitors, or additives. Gasoline/Oxygenate blends which use unleaded
gasoline and compounds that contain oxygen, such as alcohol, ethanol, MTBE, and ETBE may not
indicate that adequate or effective detergent additives are available either.
Gasoline Companies acknowledge that fuel quality is important. A number of them advertise, as
well as warrant their fuel is blended to contain the necessary additives for efficient and clean
operation of modern vehicles. Fuels available from these companies should be considered to
assure full performance and clean operation.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed.
If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as
necessary before proceeding further with this bulletin. If no DTC's are present, make sure the PCM
is at the latest software version.
If all systems are functioning as designed, ask the customer about the fuel that is being used in the
vehicle. If there is a question about the quality of the fuel, suggest that only fuels be used that are
warranted by the gasoline company against the build up of deposits.
REPAIR PROCEDURE:
Depending on the amount of deposit on the valves, there are several methods that can be used to
remove them.
1. The use of Mopar Fuel Injector Cleaner has shown reasonable results on light deposits. Add one
bottle of Mopar Fuel Injector Cleaner, p/n 4318007, to a full tank of gas.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > Customer Interest for Valve: > 18-05-97 > Feb > 97 > Engine Driveway Die Out/Rough Idle/Low Power > Page 1263
CAUTION:
UNDER NO CIRCUMSTANCES SHOULD THIS FUEL INJECTOR CLEANER BE ADDED TO A
PARTIALLY FILLED FUEL TANK.
Mopar Fuel Injector Cleaner will remove light deposits that have built up over a period of time.
However, it is not intended for continuous use. Owners should be advised of the cause of their
driveability concern and a recommendation should be made to try other brands of fuel.
2. For moderate to heavy deposits, the intake valves should be cleaned. The suggested method for
cleaning involves removal of the cylinder head from the engine. The head must be disassembled,
and the carbon removed from the valves and surrounding components with a wire brush.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption
Technical Service Bulletin # 091892A Date: 930113
Engine - Smoky Exhaust/Oil Consumption
NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993
SUBJECT: Excessive Oil Consumption 3.0L MMC Engine
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD
BE REMOVED FROM YOUR FILES.
MODELS: 1989 - 1993
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau
1990 - 1993 (AG) Daytona
1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible
1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance
1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1990 - 1991 (AQ) Chrysler TC
1988 (C) Dynasty/New Yorker
DISCUSSION:
Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve
guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve
stem seals in addition to the snap rings on the exhaust valve guides. The build code label is
located on the intake plenum.
SYMPTOM/CONDITION:
Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake
manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles
with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than
50,000 miles.
DIAGNOSIS:
Verify the PCV system is functioning properly and engine compression is within specifications.
Refer to the appropriate technical service manual for test procedures and specifications. If the PCV
system and engine compression are within specification, perform the repair procedure.
PARTS REQUIRED:
SPECIAL TOOLS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve
stem seals or cylinder head replacement as determined by inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption > Page 1268
1. Remove the intake plenum and manifold.
2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank
using the procedure in the appropriate technical service manual.
3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will
prevent the cam from possibly coming out of the journals when the engine is rotated later.
4. Check front bank cylinders in # 4, # 2, then # 6 sequence.
NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE
CYLINDER HEAD.
5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use
special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer,
valve spring and valve spring seat.
6. Remove the valve stem seals.
7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790),
measure the distance between the top of the exhaust valve guide and the top of the valve guide
boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less
the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is
.335" (8.5 mm) or more, perform PROCEDURE A.
8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence.
Procedure A
PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle)
1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide
(refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption > Page 1269
2. Using a magnet and shop towel, remove the cuttings from the cylinder head.
3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4).
4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
5. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step
4 of PROCEDURE A.
7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all
exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head.
8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs.
Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads.
9. Using the procedures in the appropriate service manual, reassemble the engine.
Procedure B
PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation
1. Remove the cylinder head using the procedure in the appropriate service manual.
2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned
to their original position at reassembly.
3. Remove all of the valve stem seals.
4. Check the height on any exhaust valve guides not already checked to determine if height
correction will be required on more than one guide.
5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height
corrected, especially the face that special tool MD998115 will contact.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption > Page 1270
6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the
combustion chamber side to provide a valve guide height from the top of the guide to the top of the
boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the
height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1
and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5
mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until
the .453" (11.5 mm) height is achieved.
7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual.
8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve
guides (refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings.
10. Install a snap ring on each exhaust valve guide (refer to fig. 4).
11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
12. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
13. Reassemble the cylinder head and install using the procedure in the appropriate service
manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to
both heads.
14. Using the procedures in the appropriate service manual, reassemble the engine.
POLICY: Reimbursable within the provisions of the warranty.
Labor Operation
TIME ALLOWANCE: Labor Operation No.
09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs.
Seals, Both Heads on Vehicle
09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs.
Remove Front Head and repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption > Page 1271
or Replace Head as Required
09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs.
Remove Rear Head and Repair or Replace Head as Required
09-35-01-95 Remove Both Heads and Repair 6.4 Hrs.
or Replace Head as Required
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 18-05-97 > Feb > 97 >
Engine - Driveway Die Out/Rough Idle/Low Power
Valve: All Technical Service Bulletins Engine - Driveway Die Out/Rough Idle/Low Power
NO: 18-05-97
GROUP: Vehicle Performance
DATE: Feb. 14, 1997
SUBJECT: Intake Valve Deposits
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-16-93, DATED NOV. 12,
1993 AND 18-20-94, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR
FILES AND NOTED IN THE 1993 AND 1994 TECHNICAL SERVICE BULLETIN MANUALS
(PUBLICATION NO's. 81-699-94000 AND 81-699-95054). ALL REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS** AND INCLUDE MODEL AND APPLICATION CHANGES.
MODELS:
**1989 - 1995** (AA) Spirit/Acclaim/LeBaron Sedan
**1988 - 1993** (AC) Dynasty/New Yorker Salon
**1990 - 1994** (AG) Daytona
**1990 - 1995** (AJ) LeBaron Coupe/LeBaron Convertible
**1992 - 1994** (AP) Shadow/Shadow Convertible/Sundance
**1987 - 1995** (AS) Town & Country/Caravan/Voyager
**1996 - 1997** (NS) Town & Country/Caravan/Voyager
**NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L ENGINE.**
SYMPTOM/CONDITION:
Driveway die out, rough idle, lack of power, sags, and hesitation.
DISCUSSION:
The above conditions may be the result of a build up of deposits on the back of the intake valves
causing blockage of fuel delivery into the upper combustion chamber. This blockage results in fuel
starvation. The deposits can be the result of fuel blending methods that have insufficient or
ineffective fuel detergent additives.
Fuel quality is a direct result of the crude oil used, the refinement process, the storage, delivery and
distribution methods, and the blending of additive compounds. Using fuel with a higher posted
octane number does not guarantee high quality, or that it is blended with adequate or effective
detergent, corrosion inhibitors, or additives. Gasoline/Oxygenate blends which use unleaded
gasoline and compounds that contain oxygen, such as alcohol, ethanol, MTBE, and ETBE may not
indicate that adequate or effective detergent additives are available either.
Gasoline Companies acknowledge that fuel quality is important. A number of them advertise, as
well as warrant their fuel is blended to contain the necessary additives for efficient and clean
operation of modern vehicles. Fuels available from these companies should be considered to
assure full performance and clean operation.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed.
If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as
necessary before proceeding further with this bulletin. If no DTC's are present, make sure the PCM
is at the latest software version.
If all systems are functioning as designed, ask the customer about the fuel that is being used in the
vehicle. If there is a question about the quality of the fuel, suggest that only fuels be used that are
warranted by the gasoline company against the build up of deposits.
REPAIR PROCEDURE:
Depending on the amount of deposit on the valves, there are several methods that can be used to
remove them.
1. The use of Mopar Fuel Injector Cleaner has shown reasonable results on light deposits. Add one
bottle of Mopar Fuel Injector Cleaner, p/n 4318007, to a full tank of gas.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 18-05-97 > Feb > 97 >
Engine - Driveway Die Out/Rough Idle/Low Power > Page 1277
CAUTION:
UNDER NO CIRCUMSTANCES SHOULD THIS FUEL INJECTOR CLEANER BE ADDED TO A
PARTIALLY FILLED FUEL TANK.
Mopar Fuel Injector Cleaner will remove light deposits that have built up over a period of time.
However, it is not intended for continuous use. Owners should be advised of the cause of their
driveability concern and a recommendation should be made to try other brands of fuel.
2. For moderate to heavy deposits, the intake valves should be cleaned. The suggested method for
cleaning involves removal of the cylinder head from the engine. The head must be disassembled,
and the carbon removed from the valves and surrounding components with a wire brush.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption
Technical Service Bulletin # 091892A Date: 930113
Engine - Smoky Exhaust/Oil Consumption
NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993
SUBJECT: Excessive Oil Consumption 3.0L MMC Engine
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD
BE REMOVED FROM YOUR FILES.
MODELS: 1989 - 1993
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau
1990 - 1993 (AG) Daytona
1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible
1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance
1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1990 - 1991 (AQ) Chrysler TC
1988 (C) Dynasty/New Yorker
DISCUSSION:
Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve
guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve
stem seals in addition to the snap rings on the exhaust valve guides. The build code label is
located on the intake plenum.
SYMPTOM/CONDITION:
Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake
manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles
with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than
50,000 miles.
DIAGNOSIS:
Verify the PCV system is functioning properly and engine compression is within specifications.
Refer to the appropriate technical service manual for test procedures and specifications. If the PCV
system and engine compression are within specification, perform the repair procedure.
PARTS REQUIRED:
SPECIAL TOOLS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve
stem seals or cylinder head replacement as determined by inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption > Page 1282
1. Remove the intake plenum and manifold.
2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank
using the procedure in the appropriate technical service manual.
3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will
prevent the cam from possibly coming out of the journals when the engine is rotated later.
4. Check front bank cylinders in # 4, # 2, then # 6 sequence.
NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE
CYLINDER HEAD.
5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use
special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer,
valve spring and valve spring seat.
6. Remove the valve stem seals.
7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790),
measure the distance between the top of the exhaust valve guide and the top of the valve guide
boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less
the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is
.335" (8.5 mm) or more, perform PROCEDURE A.
8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence.
Procedure A
PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle)
1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide
(refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption > Page 1283
2. Using a magnet and shop towel, remove the cuttings from the cylinder head.
3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4).
4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
5. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step
4 of PROCEDURE A.
7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all
exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head.
8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs.
Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads.
9. Using the procedures in the appropriate service manual, reassemble the engine.
Procedure B
PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation
1. Remove the cylinder head using the procedure in the appropriate service manual.
2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned
to their original position at reassembly.
3. Remove all of the valve stem seals.
4. Check the height on any exhaust valve guides not already checked to determine if height
correction will be required on more than one guide.
5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height
corrected, especially the face that special tool MD998115 will contact.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption > Page 1284
6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the
combustion chamber side to provide a valve guide height from the top of the guide to the top of the
boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the
height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1
and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5
mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until
the .453" (11.5 mm) height is achieved.
7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual.
8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve
guides (refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings.
10. Install a snap ring on each exhaust valve guide (refer to fig. 4).
11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
12. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
13. Reassemble the cylinder head and install using the procedure in the appropriate service
manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to
both heads.
14. Using the procedures in the appropriate service manual, reassemble the engine.
POLICY: Reimbursable within the provisions of the warranty.
Labor Operation
TIME ALLOWANCE: Labor Operation No.
09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs.
Seals, Both Heads on Vehicle
09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs.
Remove Front Head and repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption > Page 1285
or Replace Head as Required
09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs.
Remove Rear Head and Repair or Replace Head as Required
09-35-01-95 Remove Both Heads and Repair 6.4 Hrs.
or Replace Head as Required
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Technical Service Bulletins > Page 1286
Valve: Specifications
VALVES
Valve length Intake ..............................................................................................................................
...................................................................... 103.0 mm (4.055 in.)
Exhaust ................................................................................................................................................
................................................. 102.7 mm (4.043 in.)
Stem O.D. Intake .................................................................................................................................
.............................................. 7.960-7.975 mm (.3134-.3140 in.)
Exhaust ................................................................................................................................................
............................ 7.930-7.950 mm (.3122-.3130 in.)
Face angle ...........................................................................................................................................
.................................................................. 45° - 45.5°
Thickness of valve head (Margin)
Intake ...................................................................................................................................................
....................................................... 1.2 mm (.047 in.)
Limit .....................................................................................................................................................
.................................................. 0.7 mm (.028 in.)
Exhaust ................................................................................................................................................
....................................................... 2.0 mm (.079 in.)
Limit .....................................................................................................................................................
.................................................. 1.5 mm (.059 in.)
Valve stem to valve guide clearance
Intake ...................................................................................................................................................
................................ 0.03-0.06 mm (.0012-.0024 in.)
Limit .....................................................................................................................................................
.............................................. 0.10 mm (.0039 in.)
Exhaust ................................................................................................................................................
................................ 0.05-0.09 mm (.0020-.0035 in.)
Limit .....................................................................................................................................................
.............................................. 0.15 mm (.0059 in.)
Valve guide length: Intake ...................................................................................................................
........................................................................................ 44 mm (1.73 in.)
Exhaust ................................................................................................................................................
........................................................ 48 mm (1.89 in.)
Service sizes: ......................................................................................................................................
............................................................. 0.05 mm (.002 in.) Oversize ..................................................
................................................................................................................................................. 0.25
mm (.010 in.) Oversize ........................................................................................................................
........................................................................... 0.50 mm (.020 in.) Oversize
Valve seat
Width of seat contact ...........................................................................................................................
.................................... 0.9 - 1.3 mm (.035 - .051 in.)
Seat angle ...........................................................................................................................................
................................................................... 44° - 44.5°
Valve spring
Free length ..........................................................................................................................................
.................................................... 50.5 mm (1.988 in.)
Limit .....................................................................................................................................................
.............................................. 49.5 mm (1.949 in.)
Load .....................................................................................................................................................
............................. 329 N (74 lbs.) at installed height
installed height .....................................................................................................................................
.................................................. 40.4 mm (1.591 in.)
Limit .....................................................................................................................................................
.............................................. 41.4 mm (1.630 in.)
Out of squareness ...............................................................................................................................
................................................................. Less than 2°
Limit .....................................................................................................................................................
.......................................................................... 4°
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Specifications
Drive Belt: Specifications
Fig. 23 Belt deflection check points
AIR CONDITIONING BELT
Belt deflection under a ten pound push or pull should be between 1/4 to 5/16 at locations shown in
Fig. 23. Measure deflection while applying tension to accessory, then tighten mounting mounts to
specification. Deflection on a new belt should be between 1/4 to 1/2; a belt is considered used after
15 minutes of engine operation, tension on a used belt should be 1/4 and 5/16 under a tension
pound load.
ACCESSORY BELT
Correct belt tension is 5/16 deflection between pulleys.
Fig. 24 Serpentine drive belt
SERPENTINE DRIVE BELT ROUTINGS
Refer to Fig. 24, for serpentine belt routing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Specifications > Page 1291
Fig. 24 Serpentine drive belt
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Specifications > Page 1292
Drive Belt: Adjustments
Fig. 23 Belt deflection check points
AIR CONDITIONING BELT
Belt deflection under a ten pound push or pull should be between 1/4 to 5/16 at locations shown in
Fig. 23. Measure deflection while applying tension to accessory, then tighten mounting mounts to
specification. Deflection on a new belt should be between 1/4 to 1/2; a belt is considered used after
15 minutes of engine operation, tension on a used belt should be 1/4 and 5/16 under a tension
pound load.
ACCESSORY BELT
Correct belt tension is 5/16 deflection between pulleys.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > A/C Belt
Drive Belt: Service and Repair A/C Belt
Fig. 27 A/C Pulley Removal
1. Loosen adjusting locknut, then turn jack-screw, Fig. 27, counterclockwise to reduce belt tension
and remove belt.
2. When reinstalling belt, adjust belt tension to 5/16 inch deflection between pulleys.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1295
Drive Belt: Service and Repair Accessory Drive Belt
WARNING: Belts must be checked with engine not running.
ACCESSORY DRIVE BELTS
Fig. 2 Air Conditioning Belt
A/C Belt
1. Loosen Adjusting Lock Nut Fig. 2. 2. Turn adjusting "jack" screw counterclockwise to reduce belt
tension. Remove belt. 3. Reinstall. 4. Adjust belt tension. A small spring scale can be used to
establish the ten-pound belt load. Belt deflection under a ten-pound push or pull should be
between 6 mm (1/4 in.) to 8mm (5/16 in.). Tighten pulley nut to 57 Nm (40 ft. lbs.) after adjustment.
Fig. 3 Alternator/Power Steering Belt
Alternator/Power Steering Belt
1. Install breaker bar into 1/2 square opening in tensioner. 2. Rotate tensioner counterclockwise to
remove (and install) belt Fig. 3.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1296
Drive Belt: Service and Repair Alternator & Power Steering Belt
Fig. 29 Alternator & Power Steering Belt Removal. 1989-90 Models
Fig. 30 Alternator & Power Steering Belt Removal. 1990-92 Models
1. Install breaker bar into square opening in tensioner, Figs. 29 and 30.
2. ^ On 1990 and earlier models, rotate tensioner counterclockwise to remove or install belt.
^ On 1991 and later models, rotate tensioner counterclockwise to remove or install belt.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Service and Repair
Engine Accessory Bracket: Service and Repair
Fig. 28 Accessory Mounting Brackets
Expanded View
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Service and Repair > Page 1300
Accessory Mounting Brackets
1. Remove air conditioning compressor to mounting bracket screws and position compressor aside.
2. Remove A/C mounting bracket and adjustable drive belt tensioner retaining bolts. 3. Remove
steering pump belt tensioner mounting bolt and automatic belt tensioner. 4. Remove two steering
pump to engine mounting bracket screws and rear support locknut, then position power steering
pump aside. 5. Reverse procedure to install. Torque bolts to specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications
Engine Mount: Specifications
Left Motor Mount Bolt 40 ft.lb
Front Motor Mount Bolt 40 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications > Page 1304
Engine Mount: Service and Repair
Fig. 1 Engine mount replacement
RIGHT MOUNT
1. Remove right engine mount insulator vertical fasteners from frame rail. Fig. 1. 2. Remove load
on engine motor mounts by carefully supporting engine and transaxle assembly with suitable floor
jack. 3. Remove through bolt from insulator assembly. Remove insulator. 4. Reverse procedure to
install.
LEFT MOUNT
1. Raise and support vehicle. Remove left front wheel. 2. Remove inner splash shield. 3. Support
transaxle with suitable jack, then remove insulator through bolt from mount. Fig. 1. 4. Remove
transaxle mount fasteners and remove mount. 5. Reverse procedure to install.
FRONT MOUNT
1. Support engine and transaxle assembly with suitable floor jack, so it will not rotate. 2. Remove
through bolt from insulator and front crossmember mounting bracket. Fig. 1. 3. Remove front
engine mount bracket to front crossmember bolts and nuts. Remove insulator assembly. 4.
Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil
Engine Oil: Technical Service Bulletins Engine Oil - New `SG' Level Oil
Models
All 1989 And Earlier Domestic & Import Vehicles
Subject
New "SG" Quality Engine Oil
Index
LUBRICATION
Date
April 24, 1989
No.
10-01-89
(C10-01-9) BODY CODE LEGEND
ALL 1989 AND EARLIER CHRYSLER/PLYMOUTH & DODGE DOMESTIC & IMPORT VEHICLES
"SG" QUALITY ENGINE OIL
The quality of engine oil recommended for use in all Chrysler Motors' vehicles has been upgraded
to an "SG" level. The new "SG" quality engine oils can provide significant improvements
concerning sludge, varnish and wear control. These new quality oils may also be used in older
vehicles where lower quality oils (SE, SF, SF/CC) were recommended. Specific recommendations
for all 1989 vehicles may be found in the vehicle "Owners Manual".
The new "SG" engine oils are currently being introduced into the MOPAR product line in addition to
being commercially available through many automotive supply outlets.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Page 1310
Engine Oil: Specifications Oil Capacity
Oil Capacity
Crankcase Only With Filter Change
4.0 Quarts 4.5 Quarts
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Component Information > Diagrams > Diagram Information and Instructions
Oil Pressure Gauge: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Component Information > Diagrams > Diagram Information and Instructions > Page 1315
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Component Information > Diagrams > Diagram Information and Instructions > Page 1316
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Component Information > Diagrams > Page 1317
Oil Pressure Gauge: Description and Operation
The oil pressure indicating system consists of an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuates the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, increasing current flow to the gauge, resulting in an increased gauge reading.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Component Information > Diagrams > Page 1318
Oil Pressure Gauge: Testing and Inspection
Oil Pressure Gauge Pins
Combination Oil Pressure Sending Unit
1. Remove oil pressure gauge assembly from the cluster. 2. Check for continuity in wire between
oil pressure sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check
for battery voltage across B+ pin and ground pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
Lower LH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions
Oil Pressure Sender: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1324
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1325
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Service and Repair
Oil Pump: Service and Repair
REMOVAL
Fig. 19 Oil pump clearance check locations
NOTE: Oil pan must be removed prior to removing oil pump.
1. Remove timing belt. Refer to TIMING BELT & COVER.
2. Remove timing belt tensioner and crankshaft sprocket.
3. Remove oil pump assembly attaching bolts, then the oil pump.
4. Remove oil seal from oil pump housing.
INSPECTION
1. Check oil pump case for cracks and damage.
2. Using a suitable feeler gauge, measure the following clearances as follows: a.
Body
.............................................................................................................................................................
0.004-0.007 inch (0.10-0.18 mm).
b. Side
..........................................................................................................................................................
0.0015-0.0035 inch (0.04-0.09 mm).
c. Inner Rotor to Case
..................................................................................................................................... 0.001-0.002
inch (0.03-0.07 mm).
INSTALLATION
1. Install oil pump assembly and tighten attaching bolts to specifications.
2. Using oil seal installer tool No. MB998306, install new front oil seal into oil pump housing.
3. Reverse steps 1 and 2 in removal procedure, to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Intake Manifold Nuts 174 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1332
Intake Manifold: Service and Repair
1. Relieve fuel system pressure as described under Engine/Service Precautions/Technician Safety
Information/Fuel System Pressure Release. 2. Disconnect battery ground cable and drain cooling
system.
Fig. 4 Throttle Cable Removal
3. Remove air cleaner to throttle body hose, then disconnect throttle cable and transaxle kickdown
linkage, Fig. 4. 4. Disconnect Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS)
electrical connectors from throttle body. 5. Disconnect vacuum hoses from throttle body. 6.
Remove EGR tube flange from intake plenum. 7. Disconnect coolant temperature sensor and
charge temperature sensor electrical connectors. 8. Disconnect air intake plenum vacuum
connector, then disconnect fuel hoses from fuel rail.
Fig. 8 Air Intake Plenum To Intake Manifold Attaching Bolts
Fig. 9 Removing Air Intake Plenum
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1333
9. Remove air intake plenum to intake manifold attaching bolts, then air intake plenum.
10. Disconnect vacuum hoses from fuel rail and fuel pressure regulator, then disconnect fuel
injector electrical connector from engine wiring harness. 11. Remove fuel pressure regulator
attaching bolts, then loosen hose clamps and remove regulator from rail. 12. Remove fuel rail
attaching bolts, then lift fuel rail assembly from intake manifold. 13. Disconnect radiator hose from
thermostat housing and heater hose from heater pipe. 14. Remove intake manifold attaching bolts,
then intake manifold. 15. Reverse procedure to install, noting following:
a. Discard gaskets and clean gasket surfaces on both manifolds and cylinder head. b. Use a
straightedge to ensure gasket surfaces on manifolds are flat and within .004-.008 inch per foot of
manifold length.
Fig. 5 Intake Manifold Tightening Sequence
c. Torque intake manifold bolts to 20 Nm (174 in. lbs.), in sequence shown in Fig. 5. d. Tighten fuel
rail attaching bolts to specifications.
Fig. 6 Intake Plenum Tightening Sequence
e. Torque air intake plenum attaching bolts to 10-11 ft. lbs., in sequence shown in Fig. 6.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge
> Component Information > Diagrams > Diagram Information and Instructions
Oil Pressure Gauge: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge
> Component Information > Diagrams > Diagram Information and Instructions > Page 1339
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge
> Component Information > Diagrams > Diagram Information and Instructions > Page 1340
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge
> Component Information > Diagrams > Page 1341
Oil Pressure Gauge: Description and Operation
The oil pressure indicating system consists of an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuates the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, increasing current flow to the gauge, resulting in an increased gauge reading.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge
> Component Information > Diagrams > Page 1342
Oil Pressure Gauge: Testing and Inspection
Oil Pressure Gauge Pins
Combination Oil Pressure Sending Unit
1. Remove oil pressure gauge assembly from the cluster. 2. Check for continuity in wire between
oil pressure sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check
for battery voltage across B+ pin and ground pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal >
Component Information > Service and Repair
Camshaft Oil Seal: Service and Repair
Fig. 10 Checking auto lash adjuster
Oil leak or seepage at rear cam plugs may be caused by defective or missing cam plug. This
condition may be found on engines built prior to date codes of 7-593. Inspect at rear right-hand
side of engine on each cylinder head for evidence of oil leaks or seepage. If found, replace plugs,
using a light coat of RTV sealer or equivalent.
Before removing rocker arms and camshafts, check auto adjusters for freeplay. Insert a piece of
wire through bleed hole in rocker arm and carefully push adjuster check ball down, while pushing
down on check ball, move rocker arm up and down to check for freeplay. If there is no play replace
adjuster.
Fig. 3 Intake manifold tightening sequence
1. Remove intake manifold.
2. Remove valve covers.
Fig. 11 Installing auto lash adjuster retainers
3. Install auto lash adjuster retainers M0998443 or equivalent, as shown.
4. Remove distributor housing attaching bolts, then distributor housing and O-ring.
5.
When removing camshaft bearing caps do not remove bolts from bearing caps. Remove rocker
arm, rocker shafts and bearing cap as an assembly.
6. Remove camshafts, oil seals and end seals.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal >
Component Information > Service and Repair > Page 1347
7. Lubricate camshaft journals and cams with engine oil, then install camshafts on cylinder head.
Fig. 12 Camshaft bearing caps installation
8. Align camshaft bearing caps with arrows (depending on cylinder bank) as shown.
Fig. 13 Identifying bearing caps
9. Identify number 1 bearing cap as shown, then install rocker shafts into bearing cap 1 with end
notches positioned as shown, and machined portion of rocker shaft is facing down.
10. Install rocker arms, bearing caps and springs onto rocker arm shafts.
11. Temporarily install number 4 bearing cap bolts to retain assembly.
12. Apply a suitable sealant at bearing cap ends as shown.
13. Install rocker arm shaft assembly. Ensure arrow on bearing cap and arrow mark on cylinder
head are pointing in same direction.
14. Torque bearing caps as follows: a.
Numbers 3, 2, 1, then 4 to 85 inch lbs.
b. In same sequence mentioned above, torque bearing cap bolts to 180 inch lbs.
15. Install distributor housing and tighten bolts to specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal >
Component Information > Service and Repair > Page 1348
Camshaft Oil Seal
16. Lubricate camshaft oil seals lip with engine oil, then using camshaft oil seal installer tool No.
MD998713 or equivalent, install camshaft oil seals.
Camshaft End Seal
17. Using oil seal installer tool No. MB998306 or equivalent, install end seals.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Technical Service Bulletins > Customer Interest for Cylinder Head Gasket: > 090191 > Feb > 91
> Cylinder Head Gasket - Coolant Leakage
Cylinder Head Gasket: Customer Interest Cylinder Head Gasket - Coolant Leakage
SUBJECT: Head Gasket Coolant Leakage, 3.0L Engine
NO.: 09-01-91
GROUP: ENGINE
DATE: Feb. 25, 1991
MODELS:
1987 - 1989 (S/AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
1988 - 1989 (C/AC) DYNASTY/NEW YORKER
1989 (AA) SPIRIT/ACCLAIM
SYMPTOM/CONDITION:
Some 1987-1989 vehicles equipped with the 3.0L engine may experience loss of engine coolant
from an external cylinder head(s) gasket leak.
A new head gasket, PN MD143540, entered engine production December 1988, beginning with
engine serial number MM6619.
NOTE: THE ENGINE SERIAL NUMBER IS LOCATED ON THE MACHINED SURFACE ON THE
RIGHT REAR SIDE OF THE ENGINE BLOCK.
DIAGNOSIS:
Attach a radiator pressure tester and apply 15 psi pressure. Carefully inspect the engine for coolant
leakage. If leakage is present at the cylinder head(s) to block mating surfaces perform the repair
procedure.
If no leakage is evident at the head(s) to block mating surfaces but pressure test indicates leakage,
continue the leakage diagnosis as outlined in the Cooling System section of the appropriate
Service Manual and repair as required.
PARTS REQUIRED:
1 - Cylinder Head Gasket Kit PN MD172539
Gasket Kit Contains
2 - Head Gaskets PN MD143540
2 - Intake Manifold Gaskets PN MD157195
2 - Surge Tank Gaskets PN MD094128
REPAIR PROCEDURE:
This repair involves removing BOTH cylinder heads and replacing the cylinder head gaskets even
though the leakage is evident from one bank only.
1. Drain the cooling system.
2. Turn the ignition key to the off position and disconnect the battery negative battery cable.
3. Remove both cylinder heads as outlined in the appropriate Service Manual.
4. Clean the cylinder heads and block mating surfaces.
5. Check cylinder head(s) flatness as outlined in the appropriate Service Manual.
6. Install both cylinder heads as outlined in the appropriate Service Manual.
7. Fill cooling system as outlined in the appropriate Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Technical Service Bulletins > Customer Interest for Cylinder Head Gasket: > 090191 > Feb > 91
> Cylinder Head Gasket - Coolant Leakage > Page 1357
8. Connect the negative battery cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
Labor Operation No. 09-35-30-90 . . . . . . . . . 5.3 Hrs.
FAILURE CODE: 65 - Leaks
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: >
090191 > Feb > 91 > Cylinder Head Gasket - Coolant Leakage
Cylinder Head Gasket: All Technical Service Bulletins Cylinder Head Gasket - Coolant Leakage
SUBJECT: Head Gasket Coolant Leakage, 3.0L Engine
NO.: 09-01-91
GROUP: ENGINE
DATE: Feb. 25, 1991
MODELS:
1987 - 1989 (S/AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
1988 - 1989 (C/AC) DYNASTY/NEW YORKER
1989 (AA) SPIRIT/ACCLAIM
SYMPTOM/CONDITION:
Some 1987-1989 vehicles equipped with the 3.0L engine may experience loss of engine coolant
from an external cylinder head(s) gasket leak.
A new head gasket, PN MD143540, entered engine production December 1988, beginning with
engine serial number MM6619.
NOTE: THE ENGINE SERIAL NUMBER IS LOCATED ON THE MACHINED SURFACE ON THE
RIGHT REAR SIDE OF THE ENGINE BLOCK.
DIAGNOSIS:
Attach a radiator pressure tester and apply 15 psi pressure. Carefully inspect the engine for coolant
leakage. If leakage is present at the cylinder head(s) to block mating surfaces perform the repair
procedure.
If no leakage is evident at the head(s) to block mating surfaces but pressure test indicates leakage,
continue the leakage diagnosis as outlined in the Cooling System section of the appropriate
Service Manual and repair as required.
PARTS REQUIRED:
1 - Cylinder Head Gasket Kit PN MD172539
Gasket Kit Contains
2 - Head Gaskets PN MD143540
2 - Intake Manifold Gaskets PN MD157195
2 - Surge Tank Gaskets PN MD094128
REPAIR PROCEDURE:
This repair involves removing BOTH cylinder heads and replacing the cylinder head gaskets even
though the leakage is evident from one bank only.
1. Drain the cooling system.
2. Turn the ignition key to the off position and disconnect the battery negative battery cable.
3. Remove both cylinder heads as outlined in the appropriate Service Manual.
4. Clean the cylinder heads and block mating surfaces.
5. Check cylinder head(s) flatness as outlined in the appropriate Service Manual.
6. Install both cylinder heads as outlined in the appropriate Service Manual.
7. Fill cooling system as outlined in the appropriate Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: >
090191 > Feb > 91 > Cylinder Head Gasket - Coolant Leakage > Page 1363
8. Connect the negative battery cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
Labor Operation No. 09-35-30-90 . . . . . . . . . 5.3 Hrs.
FAILURE CODE: 65 - Leaks
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal
Cylinder Head Gasket: Service and Repair Cylinder Head Removal
Fig. 1 Cylinder Head-Camshaft-Valves
Fig. 2 Rocker Cover
REMOVE VALVE COVERS
1. Remove air cleaner assembly. 2. Disconnect battery and relocate spark plug wires. 3. Remove
vacuum connections. 4. Remove rocker cover screws and remove cover Fig. 2.
REMOVE CAMSHAFT SPROCKETS
Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove
camshaft sprockets. See: Timing Components/Timing Belt/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 1366
Fig. 3 Auto Lash Adjuster Check
CHECK AUTO LASH ADJUSTER FUNCTION
Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker
arm and VERY LIGHTLY push the auto adjuster ball check down Fig. 3. While lightly holding the
check ball down move the rocker up and down to check for free play. If there is no play replace the
adjuster.
NOTE: Do not disassemble the auto lash adjuster.
Fig. 4 Auto Lash Adjuster Retainers
REMOVE CAMSHAFTS
1. Install auto lash adjuster retainers. Fig. 4.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 1367
Fig. 11 Distributor Drive
2. Remove distributor extension Fig. 11. 3. When removing camshaft bearing caps do not remove
the bolts from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an
assembly.
Fig. 5 Check Camshafts
INSPECT CAMSHAFTS
1. Inspect camshaft bearing journals for damage and binding Fig. 5. If journals are binding, also
check the cylinder head for damage Fig. 1. Also
check cylinder head oil holes for clogging.
2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the
camshaft and replace if abnormal wear is evident
Fig. 5.
3. Check the cam surface for abnormal wear and damage and replace if defective. Also measure
the cam height Fig. 5.and replace if out of limit,
standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch.
Fig. 6 Inspect Rocker Arms
INSPECT ROCKER ARMS
Check rocker arms for wear or damage Fig. 6. Replace as necessary.
INSPECT ROCKER ARM SHAFTS
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 1368
Fig. 7 Rocker Arm Shaft Identification
NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on
the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does
not have this oil passage Fig. 7.
1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily
damaged or worn. 2. Check oil holes for clogging with small wire, clean as required Fig. 7.
REMOVE INTAKE MANIFOLD ASSEMBLY
Refer to Engine/Intake Manifold/Service and Repair. See: Intake Manifold/Service and Repair
REMOVE EXHAUST MANIFOLDS
Remove exhaust manifolds and cross over, Refer to Exhaust System/Exhaust Manifold/Service
and Repair. See: Exhaust System/Exhaust Manifold/Service and Repair
REMOVE CYLINDER HEADS
Fig. 14 Cylinder Head Bolt Removal Sequence
Remove cylinder head bolts in sequence shown in Fig. 14 and remove cylinder head.
INSPECTION
1. Before cleaning, check for leaks, damage and cracks. 2. Clean cylinder head and oil passages.
Fig. 15 Check Cylinder Head
3. Check cylinder head for flatness Fig. 15. 4. Cylinder head must be flat within:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 1369
^ Standard dimension = less than 0.05mm .002 inch
^ Service Limit = 0.2mm .008 inch
^ Grinding Limit = Maximum of 0.2 mm .008 inch is permitted.
CAUTION: This is a combined total dimension of stock removal from cylinder head if any and block
top surface.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 1370
Cylinder Head Gasket: Service and Repair Cylinder Head Installation
INSTALL HEADS
1. Clean surfaces of head and block, install head gasket over locating dowels. 2. Install head on
locating dowels. 3. Install 10mm Allen Hex head bolts with washers.
Fig. 16 Cylinder Head Bolt Tightening Sequence
4. Tighten bolts in the order shown in Fig. 16. When tightening the cylinder head bolts, tighten
gradually, working in two or three steps and finally
tighten to specified torque of 108 Nm 80 ft. lbs..
INSTALL CAMSHAFTS
Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head.
Fig. 8 Camshaft Bearing Caps Position
REASSEMBLE ROCKER ARMS
1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown in
Fig. 8 and in numerical order.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 1371
Fig. 9 Number One Camshaft Bearing Cap
NOTE: Identify number one bearing cap number one and number four caps are similar Fig. 9.
Fig. 10 Assemble Rocker Arm And Shafts
2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs.
9 and 10 note that the machined portion of the
rocker shaft is facing down.
3. Insert attaching bolts to retain assembly.
INSTALL ROCKER ARM SHAFT ASSEMBLY
1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in Fig. 8. 2. Install
the rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow
mark on the cylinder head are in the same
direction Fig. 8.
NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other.
3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and #
4. 4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 1372
Fig. 11 Distributor Drive
5. Install distributor drive adaptor assembly Fig. 11.
Fig. 1 Cylinder Head-Camshaft-Valves
Fig. 2 Rocker Cover
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Service and Repair > Cylinder Head Removal > Page 1373
INSTALL VALVE COVERS
1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. See Fig. 2 and apply
sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. 3. Install cover and
tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket >
Component Information > Technical Service Bulletins > Customer Interest for Valve Cover Gasket: > 091689 > Oct > 89 >
Engine - Oil Consumption
Valve Cover Gasket: Customer Interest Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket >
Component Information > Technical Service Bulletins > Customer Interest for Valve Cover Gasket: > 091689 > Oct > 89 >
Engine - Oil Consumption > Page 1382
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover Gasket: > 091689 >
Oct > 89 > Engine - Oil Consumption
Valve Cover Gasket: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover Gasket: > 091689 >
Oct > 89 > Engine - Oil Consumption > Page 1388
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption
Technical Service Bulletin # 091892A Date: 930113
Engine - Smoky Exhaust/Oil Consumption
NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993
SUBJECT: Excessive Oil Consumption 3.0L MMC Engine
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD
BE REMOVED FROM YOUR FILES.
MODELS: 1989 - 1993
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau
1990 - 1993 (AG) Daytona
1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible
1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance
1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1990 - 1991 (AQ) Chrysler TC
1988 (C) Dynasty/New Yorker
DISCUSSION:
Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve
guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve
stem seals in addition to the snap rings on the exhaust valve guides. The build code label is
located on the intake plenum.
SYMPTOM/CONDITION:
Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake
manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles
with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than
50,000 miles.
DIAGNOSIS:
Verify the PCV system is functioning properly and engine compression is within specifications.
Refer to the appropriate technical service manual for test procedures and specifications. If the PCV
system and engine compression are within specification, perform the repair procedure.
PARTS REQUIRED:
SPECIAL TOOLS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve
stem seals or cylinder head replacement as determined by inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption > Page 1397
1. Remove the intake plenum and manifold.
2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank
using the procedure in the appropriate technical service manual.
3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will
prevent the cam from possibly coming out of the journals when the engine is rotated later.
4. Check front bank cylinders in # 4, # 2, then # 6 sequence.
NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE
CYLINDER HEAD.
5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use
special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer,
valve spring and valve spring seat.
6. Remove the valve stem seals.
7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790),
measure the distance between the top of the exhaust valve guide and the top of the valve guide
boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less
the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is
.335" (8.5 mm) or more, perform PROCEDURE A.
8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence.
Procedure A
PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle)
1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide
(refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption > Page 1398
2. Using a magnet and shop towel, remove the cuttings from the cylinder head.
3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4).
4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
5. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step
4 of PROCEDURE A.
7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all
exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head.
8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs.
Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads.
9. Using the procedures in the appropriate service manual, reassemble the engine.
Procedure B
PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation
1. Remove the cylinder head using the procedure in the appropriate service manual.
2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned
to their original position at reassembly.
3. Remove all of the valve stem seals.
4. Check the height on any exhaust valve guides not already checked to determine if height
correction will be required on more than one guide.
5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height
corrected, especially the face that special tool MD998115 will contact.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption > Page 1399
6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the
combustion chamber side to provide a valve guide height from the top of the guide to the top of the
boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the
height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1
and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5
mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until
the .453" (11.5 mm) height is achieved.
7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual.
8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve
guides (refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings.
10. Install a snap ring on each exhaust valve guide (refer to fig. 4).
11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
12. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
13. Reassemble the cylinder head and install using the procedure in the appropriate service
manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to
both heads.
14. Using the procedures in the appropriate service manual, reassemble the engine.
POLICY: Reimbursable within the provisions of the warranty.
Labor Operation
TIME ALLOWANCE: Labor Operation No.
09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs.
Seals, Both Heads on Vehicle
09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs.
Remove Front Head and repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 >
Engine - Smoky Exhaust/Oil Consumption > Page 1400
or Replace Head as Required
09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs.
Remove Rear Head and Repair or Replace Head as Required
09-35-01-95 Remove Both Heads and Repair 6.4 Hrs.
or Replace Head as Required
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A >
Jan > 93 > Engine - Smoky Exhaust/Oil Consumption
Technical Service Bulletin # 091892A Date: 930113
Engine - Smoky Exhaust/Oil Consumption
NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993
SUBJECT: Excessive Oil Consumption 3.0L MMC Engine
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD
BE REMOVED FROM YOUR FILES.
MODELS: 1989 - 1993
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau
1990 - 1993 (AG) Daytona
1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible
1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance
1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1990 - 1991 (AQ) Chrysler TC
1988 (C) Dynasty/New Yorker
DISCUSSION:
Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve
guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve
stem seals in addition to the snap rings on the exhaust valve guides. The build code label is
located on the intake plenum.
SYMPTOM/CONDITION:
Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake
manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles
with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than
50,000 miles.
DIAGNOSIS:
Verify the PCV system is functioning properly and engine compression is within specifications.
Refer to the appropriate technical service manual for test procedures and specifications. If the PCV
system and engine compression are within specification, perform the repair procedure.
PARTS REQUIRED:
SPECIAL TOOLS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve
stem seals or cylinder head replacement as determined by inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A >
Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1406
1. Remove the intake plenum and manifold.
2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank
using the procedure in the appropriate technical service manual.
3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will
prevent the cam from possibly coming out of the journals when the engine is rotated later.
4. Check front bank cylinders in # 4, # 2, then # 6 sequence.
NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE
CYLINDER HEAD.
5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use
special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer,
valve spring and valve spring seat.
6. Remove the valve stem seals.
7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790),
measure the distance between the top of the exhaust valve guide and the top of the valve guide
boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less
the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is
.335" (8.5 mm) or more, perform PROCEDURE A.
8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence.
Procedure A
PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle)
1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide
(refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A >
Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1407
2. Using a magnet and shop towel, remove the cuttings from the cylinder head.
3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4).
4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
5. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step
4 of PROCEDURE A.
7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all
exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head.
8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs.
Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads.
9. Using the procedures in the appropriate service manual, reassemble the engine.
Procedure B
PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation
1. Remove the cylinder head using the procedure in the appropriate service manual.
2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned
to their original position at reassembly.
3. Remove all of the valve stem seals.
4. Check the height on any exhaust valve guides not already checked to determine if height
correction will be required on more than one guide.
5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height
corrected, especially the face that special tool MD998115 will contact.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A >
Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1408
6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the
combustion chamber side to provide a valve guide height from the top of the guide to the top of the
boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the
height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1
and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5
mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until
the .453" (11.5 mm) height is achieved.
7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual.
8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve
guides (refer to Fig. 2 and 3).
a. Install the special tool on the exhaust valve guide.
b. Turn the tool clockwise until the force required to turn the tool suddenly decreases.
c. Remove the tool.
9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings.
10. Install a snap ring on each exhaust valve guide (refer to fig. 4).
11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790
and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will
not fit between special tool and top of valve guide) install the valve spring seat. Install all of the
intake valve spring seats.
12. Install new valve stem seals on the intake and exhaust valve guides using special tool
MD998729.
13. Reassemble the cylinder head and install using the procedure in the appropriate service
manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to
both heads.
14. Using the procedures in the appropriate service manual, reassemble the engine.
POLICY: Reimbursable within the provisions of the warranty.
Labor Operation
TIME ALLOWANCE: Labor Operation No.
09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs.
Seals, Both Heads on Vehicle
09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs.
Remove Front Head and repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A >
Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1409
or Replace Head as Required
09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs.
Remove Rear Head and Repair or Replace Head as Required
09-35-01-95 Remove Both Heads and Repair 6.4 Hrs.
or Replace Head as Required
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations
Oil Pressure Sender: Locations
Lower LH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions
Oil Pressure Sender: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1416
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1417
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Testing and Inspection
Timing Belt: Testing and Inspection
ABNORMAL NOISES FROM TIMING BELT
Incorrect Belt Tension
Timing belts which are too loose or too tight are prone to making a humming sound, especially on
heavy deceleration. Inspect the timing belt and re-adjust the tension.
Pulley or Belt Rubbing on Cover
A rubbing or whining sound can occur when the pulleys (or belt) are rubbing against the timing
covers. Remove the covers and inspect for wear. If the timing belt shows any signs of wear or fraying along
the outer edge it should be replaced.
- Inspect the pulleys for proper alignment. An incorrectly placed washer or spacer may move one
pulley out of alignment with the rest.
- Verify all pulleys have no lateral movement (wobble) . Replace any pulley which wobbles.
- Verify the timing cover is not warped. The cover should be replaced if warped.
- Verify the timing cover rubber gasket is properly installed.
Incorrect Type of Timing Belt
Timing belt teeth are available in several different types. Compare the new belt to the old one and
verify the teeth are the same shape. Timing belt types are not interchangeable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks
Timing Belt: Service and Repair Initial Checks
INITIAL CHECKS (PRIOR TO REMOVAL)
PURPOSE
Checking and recording the ignition timing and manifold vacuum level before and after the timing
belt replacement allows for two assurances: Initial conditions are correct.
- Verifies the quality of the job after the belt has been installed.
WHY
Ignition Timing
Ignition timing is the position of the piston on its compression stroke when the ignition coil fires the
associated sparkplug.
Ignition timing is affected by two sources. Physical rotation of the distributor.
- Alignment of the camshaft and crankshaft via the timing belt.
Prior to replacing the timing belt it is very important to verify that this relationship is correct. If the
timing belt is installed correctly the after-repairs timing check should be within 2 degrees of the
pre-repairs timing check.
NOTE: Minor differences, +/- 2 degrees may result from original belt stretching as it aged.
If the timing belt is initially installed incorrectly, the prerepairs ignition timing may not be correct,
and the after-repairs timing will differ greatly from the initial.
Checking the timing before and after the job will help prevent confusion and verify the job was done
correctly.
Notes on Timing: An ignition timing of 0 degrees BTDC (Before Top Dead Center) implies that the ignition coil fires
the spark exactly as the piston reaches its highest position (top dead center).
- An ignition timing of 10 degrees BTDC implies that the spark is triggered 10 degrees of crankshaft
rotation Before to the piston reaching top dead center.
- An ignition timing of 10 degrees IT'D implies that the spark is triggered 10 degrees of crank shaft
rotation After the piston reaches top dead center.
Manifold Vacuum
If the camshaft is out of alignment with the crankshaft, the intake and exhaust valves will not open
and close at the optimum times. This will reduce the volumetric efficiency of the engine and thus
reduce the manifold vacuum level.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1424
NOTE: The ignition timing will also affect the manifold vacuum levels, verify the timing is correct
prior to measuring the vacuum.
If the after-repair vacuum level is lower than the pre-repairs level this would be an indication that
the timing belt may not be installed correctly.
NOTE: The vacuum checks should be made at similar engine speeds and temperatures.
- Check "manifold vacuum" at a source downstream of the throttle plates.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1425
Timing Belt: Service and Repair Pre-Installation Inspection
PRE-INSTALLATION INSPECTION
- Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or
damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt
mating surface will require the pulley to be replaced.
- Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp,
causing the pulleys or belts to rub against the inside of the cover.
- Inspect the tensioner and water pump pulleys for wobble or looseness. The pulleys should spin
freely with no rough spots or lateral (side-to-side) movement.
- Inspect the tensioner and water pump pulley surfaces. They should be clean and free of nicks and
burrs. If any damage is noted the pulleys should be replaced.
- Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage
should be replaced.
WARNING: Oil leakage will damage the new timing belt.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1426
Timing Belt: Service and Repair Timing Belt Removal and Installation
Removal
NOTE: Always carefully inspect the Water Pump when replacing the Timing Belt, as the pump is
timing belt driven.
Fig. 5 Accessories & mounting brackets removal & installation
1. Disconnect battery ground cable.
Air Conditioning Belt
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1427
Alternator/Power Steering Belt
2. Remove accessory drive belts.
a Loosen adjusting lock nut on A/C belt adjuster, Turn adjusting jack screw counterclockwise to
reduce belt tension.
b Install breaker bar into 1/2 square opening in tensioner on Alternator/Power Steering belt. Rotate
tensioner counterclockwise to remove belt.
3. Remove A/C compressor, alternator, power steering pump, tensioners and mounting brackets as
shown in Fig. 5, and set aside.
Right Inner Splash Shield - Typical
4. Raise and support vehicle, then remove right inner splash shield.
Fig. 6 Crankshaft pulley removal
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1428
5. Remove crankshaft drive pulleys and torsional damper, Fig. 6, then lower vehicle and position a
suitable jack under engine.
Fig. 7 Engine mount removal - Typical
6. Remove engine mount insulator from engine mount bracket, raise engine slightly, then remove
engine mount bracket as shown in Fig. 7.
Fig. 8 Timing belt cover removal
7. Remove timing belt covers as shown in Fig. 8. 8. If belt is to be reused, mark belt running
direction for reassembly reference.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1429
Fig. 9 Timing Belt Routing
9. Loosen timing belt tensioner, Fig. 9, then remove timing belt.
10. Remove crankshaft sprocket flange, if necessary. 11. Remove camshaft sprocket attaching
bolts, then the sprockets, if necessary.
Camshaft Sprockets
12. Install camshaft sprockets, then using camshaft sprocket holder tool MB990775, torque bolts to
73 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1430
Fig. 10 Positioning timing belt tensioner
13. Install timing belt tensioner and spring. Rotate tensioner counterclockwise, Fig. 10, then
temporarily tighten bolt. 14. Install timing belt on crankshaft sprocket first, while keeping belt tight
on tension side, then position belt over front camshaft sprocket, Fig. 9. 15. Then, install belt on
water pump pulley and rear camshaft sprocket and finally on the timing belt tensioner, Fig. 9. 16.
Rotate front camshaft sprocket in opposite direction and check that all timing marks align, Fig. 9.
17. Install crankshaft sprocket flange, then loosen tensioner bolt to allow spring to tension belt.
Rotate crankshaft two complete revolutions, in
direction of normal rotation and check timing marks.
18. Tighten tensioner bolt to 23 ft. lbs. 19. Install timing belt covers as shown in Fig. 8. 20. Install
engine brackets, pulleys, and accessories as shown in Fig. 5, then the drive belts.
Installation
NOTE: Always carefully inspect the Water Pump when replacing the Timing Belt, as the pump is
timing belt driven.
Camshaft Sprockets
1. Install camshaft sprockets, then using camshaft sprocket holder tool MB990775, torque bolts to
73 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1431
Fig. 10 Positioning timing belt tensioner
2. Install timing belt tensioner and spring. Rotate tensioner counterclockwise, Fig. 10, then
temporarily tighten bolt.
Fig. 9 Timing Belt Routing
3. Install timing belt on crankshaft sprocket first, while keeping belt tight on tension side, then
position belt over front camshaft sprocket, Fig. 9. 4. Then, install belt on water pump pulley and
rear camshaft sprocket and finally on the timing belt tensioner, Fig. 9. 5. Rotate front camshaft
sprocket in opposite direction and check that all timing marks align, Fig. 9. 6. Install crankshaft
sprocket flange, then loosen tensioner bolt to allow spring to tension belt. Rotate crankshaft two
complete revolutions, in
direction of normal rotation and check timing marks.
7. Tighten tensioner bolt to 23 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1432
Fig. 8 Timing belt cover removal
8. Install timing belt covers as shown in Fig. 8.
Fig. 5 Accessories & mounting brackets removal & installation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Initial Checks > Page 1433
Air Conditioning Belt
Alternator/Power Steering Belt
Fig. 7 Engine mount removal - Typical
9. Install engine brackets, pulleys, and accessories as shown in Fig. 5, then the drive belts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Service and Repair > Page 1434
Timing Belt: Tools and Equipment
RECOMMENDED TOOLS
- Floor jack (for supporting the engine while removing the front engine mount).
- Timing light (for measuring timing before and after).
- Vacuum gauge (for measuring engine vacuum levels before and after).
Crankshaft Pulley Removal
- Crankshaft Holding Tool MD998784 (used in conjunction with an old drive belt), or an air powered
impact gun (for removing the crankshaft bolt).
Timing Belt Tensioner Release
- Large flat blade screw driver (for moving timing belt tensioner).
- Torque Wrenches: Low Range (0-50 ft-lb) for covers and brackets.
- High Range (0-150 ft-lb) for crankshaft pulley bolt.
- Full set of Metric sockets and wrenches.
- Fender covers.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information
Timing Belt: Fundamentals and Basics General Information
TIMING BELT, GENERAL INFORMATION
PURPOSE
The timing belt synchronizes (times) the opening and closing of the intake and exhaust valves with
the movement/stroke of the pistons. The timing belt also matches the rotation of the distributor with
the movement of the pistons.
OPERATION
The crankshaft represents the movement of the pistons while the camshaft controls the opening
and closing of the valves. The timing belt connects the crankshaft to the camshaft and uses the
rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of
the crankshaft the camshaft is rotated only once.
Why 2:1
In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and
exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must
rotate two full revolutions.
The camshaft controls the opening and closing of the valves. During the four piston strokes of an
engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This
requires only one revolution of the camshaft.
NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves
will open and close only during the exhaust stroke. During the compression and power strokes the
valves remain closed.
How
This 2 to 1 reduction is accomplished by making the circumference of the camshaft pulley twice as
large as the crankshaft pulley. This allows the smaller crankshaft to complete two revolutions while
the larger camshaft completes only one revolution.
NOTE: The distributor also requires only one rotation for every two rotations of the crankshaft.
FIRST INDICATIONS OF A BROKEN BELT
1. The engine will immediately die or fail to start. 2. When attempting to restart the engine, the
cranking speed (rpm) will be unusually fast. 3. The sound of the engine while attempting to restart
will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir..." cranking sound
it will sound more like "RirRirRirRir" with no detectable rhythm.
Why When the timing belt brakes the camshaft and distributor quit rotating.
- Without distributor rotation the ignition system stops producing spark and the engine immediately
dies or fails to start.
- Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This
prevents the pistons from developing compression which also causes the engine to die. This lack
of compression also produces the unusually fast and non- rhythmic cranking speed when
attempting to restart the engine.
NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each
piston begins its compression stroke.
VERIFYING TIMING BELT IS BROKEN
Check for camshaft rotation while cranking the engine (with the starter or by hand, using the
crankshaft bolt).
WARNING: When rotating the crankshaft by hand always disconnect the battery.
Camshaft rotation can be verified by: Remove oil filler cap and check if camshaft is visible.
- Remove valve cover and directly observe camshaft.
- Remove distributor cap and check for rotor rotation (the rotor is driven by the camshaft)
- Remove upper timing belt cover and check camshaft pulley rotation and belt integrity.
Other Indications the Timing Belt may be broken. No ignition spark.
- Very low compression (<15 psi) on all cylinders. Due to the low compression the following
additional symptoms may be present. While attempting to start the car, the battery strength remains high for an unusually long length of
time.
- The sound of the engine while attempting to restart will be different than normal. Instead of the
usual rhythmic "Rir.. .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no
detectable rhythm.
NOTE: For an experienced technician this unique sound will often be the initial symptom that leads
to a more in-depth check of the timing belt.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1437
OTHER RELATED PROBLEMS
The Timing Belt has Jumped Teeth If the belt is excessively worn, loose, or missing teeth it is possible for the belt to jump teeth on the
crankshaft.
- A belt which is off by just one tooth will cause an engine to run very poorly or not run at all.
A belt which is off by more than one tooth will generally prevent the engine from starting.
To verify the problem, remove the timing belt covers and check the crankshaft and camshaft
alignment marks.
The Camshaft is Seized
- A seized camshaft will produce the same symptoms as a broken timing belt.
WARNING: Rotating the camshaft with the timing belt removed on an interference engine can
result in additional valve damage.
INTERFERENCE/FREE RUNNING
Interference - Upon reaching Top Dead Center a piston will impact a valve which is fully open. This
situation occurs when the timing belt breaks and a valve is left fully open while the pistons continue
to operate.
NOTE: This engine is an Interference design.
Free Running - The engine has been designed such that should the timing belt break there will still
be clearance between a fully open valve and a piston at TDC.
Valve Damage - Interference engines will generally bend intake or exhaust valves when a timing
belt is broken. When a timing belt breaks the rotational momentum of the camshaft will cause
several valves to open and close out of sequence with the movement of the pistons.
Any valve which is left open when the associated piston reaches TDC will be struck and bent. Bent
valves will generally stick in a partially open position, resulting in a loss of vacuum and
compression on that cylinder.
If a timing belt breaks during normal city or highway driving the probability that an interference
engine will bend at least one valve is very high.
NOTE: If a timing belt breaks, an interference type engine will not always bend or damage valves.
If the timing belt breaks during start-up with camshaft remaining in a position where no valve is fully
open there will be no valve damage.
Free running engines will generally not bend or damage valves when a timing belt is broken.
However the design clearance between a fully open valve and a piston at TDC may be quite small
(<0.020 inches) . A build up of carbon on top of the piston in conjunction with improperly adjusted
valve clearances can result in a free running engine bending valves when the timing belt breaks.
VERIFYING VALVE DAMAGE
Install a new timing belt with the camshaft and crankshaft aligned properly and attempt to start the
engine. If the engine starts and runs smoothly with steady high vacuum levels, the valves are not
damaged.
WARNING: Rotating the camshaft with the timing belt removed on an interference engine can
result in additional valve damage.
If the engine fails to start or runs roughly with the manifold vacuum reading rapidly oscillating over
a 4-6 inch range there may be valve damage.
NOTE: Verify that the crankshaft and camshaft are aligned properly. A timing belt which is off Dust
one tooth may produce similar performance symptoms.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1438
Remove the valve cover and inspect the valve clearances. A valve which is bent will be stuck in the
open position or will have an excessively larger clearance.
Perform a compression check or a cylinder leak down check. Cylinders with bent valves will have
very low compression (<50.0 psi) and will not hold pressure.
If valve damage is detected the cylinder head will have to be removed and the damaged valves
replaced. Also inspect top of the pistons for damage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1439
Timing Belt: Fundamentals and Basics Initial Preparations
INITIAL PREPARATIONS
Disconnect Battery
When working near or around the crankshaft/camshaft pulleys, accidentally engaging the starter
can result in serious personal injury and major engine damage.
The negative battery terminal should be disconnected prior to commencing work and should not be
reconnected until the timing belt is re-installed and the engine is ready to start.
Remove Front Tire
Access to lower timing belt components can be gained by removing the associated front tire and
working through the wheel well.
Fender Covers
Fender covers will prevent damage to the vehicles finish while performing the job.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1440
Timing Belt: Fundamentals and Basics Positioning Crankshaft to Number 1 TDC
POSITIONING CRANKSHAFT TO #1 TDC, Compression
NOTE: If the timing belt is broken, pre-position only the crankshaft and ignore references in this
article to compression stroke, camshaft, and distributor position. Rotating the camshaft with a
broken timing belt may damage the valves.
WHY
Timing belt installation alignment marks correspond to the crankshaft positioned at #1 Top Dead
Center (TDC), during the compression stroke. Moving the crankshaft to this point prior to removing
the belt allows you to verify the original alignment of the crankshaft and camshaft. This also
reduces crank/cam pulley movement once the belt is removed which helps to minimize any
possible confusion.
The alignment marks may be dirty and difficult to locate. Pre-positioning the crankshaft will make it
easier to locate the marks.
HOW
- Remove the distributor cap and observe the position of the rotor.
- Using the crankshaft bolt, rotate the crankshaft until the distributor rotor is nearly pointing towards
the #1 cylinder position.
- Then slowly rotate the crankshaft until the timing indicator is pointing at the "0"/TDC degree mark.
NOTE: Remember that the crankshaft rotates twice for every rotation of the camshaft. The rotor
must be pointing towards #1 cylinder terminal when the timing mark reaches 0 degrees.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1441
Timing Belt: Fundamentals and Basics Removal and Installation Tips and Hints (Maintenance)
TIMING BELT REMOVAL
- Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be
removed to replace the timing belt it would be convenient to have any necessary replacement belts
on hand should any the drive belts show excessive wear.
- After the timing belt covers are removed, verify the camshaft and crankshaft are properly aligned.
- Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets
or covers could allow moisture and debris to enter the covers and damage the belt.
NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing
belt or between the belt and the pulley, resulting in the belt skipping teeth.
- When removing the engine mount, Slightly raise the engine with a floor jack. This will take the
weight of the engine off of engine mount bolts and will ease in removal.
CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of
wood or other soft material to prevent puncturing the oil pan.
TIMING BELT INSTALLATION
- When positioning or removing the camshaft and crankshaft pulleys, do not grasp the teeth of the
pulleys with pliers or any other metal object.
CAUTION: Any nick or burr left on the pulleys may result in premature belt failure.
- When installing the timing belt: Do not use any device to pry the belt over a pulley
- Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on.
- Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack
is left on the opposite side, when the tensioner is released the pulleys will turn and the belt
alignment will be incorrect.
- After installing and tensioning the belt, recheck the alignment of the camshafts and crankshaft.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1442
Timing Belt: Fundamentals and Basics
General Information
TIMING BELT, GENERAL INFORMATION
PURPOSE
The timing belt synchronizes (times) the opening and closing of the intake and exhaust valves with
the movement/stroke of the pistons. The timing belt also matches the rotation of the distributor with
the movement of the pistons.
OPERATION
The crankshaft represents the movement of the pistons while the camshaft controls the opening
and closing of the valves. The timing belt connects the crankshaft to the camshaft and uses the
rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of
the crankshaft the camshaft is rotated only once.
Why 2:1
In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and
exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must
rotate two full revolutions.
The camshaft controls the opening and closing of the valves. During the four piston strokes of an
engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This
requires only one revolution of the camshaft.
NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves
will open and close only during the exhaust stroke. During the compression and power strokes the
valves remain closed.
How
This 2 to 1 reduction is accomplished by making the circumference of the camshaft pulley twice as
large as the crankshaft pulley. This allows the smaller crankshaft to complete two revolutions while
the larger camshaft completes only one revolution.
NOTE: The distributor also requires only one rotation for every two rotations of the crankshaft.
FIRST INDICATIONS OF A BROKEN BELT
1. The engine will immediately die or fail to start. 2. When attempting to restart the engine, the
cranking speed (rpm) will be unusually fast. 3. The sound of the engine while attempting to restart
will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir..." cranking sound
it will sound more like "RirRirRirRir" with no detectable rhythm.
Why When the timing belt brakes the camshaft and distributor quit rotating.
- Without distributor rotation the ignition system stops producing spark and the engine immediately
dies or fails to start.
- Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This
prevents the pistons from developing compression which also causes the engine to die. This lack
of compression also produces the unusually fast and non- rhythmic cranking speed when
attempting to restart the engine.
NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each
piston begins its compression stroke.
VERIFYING TIMING BELT IS BROKEN
Check for camshaft rotation while cranking the engine (with the starter or by hand, using the
crankshaft bolt).
WARNING: When rotating the crankshaft by hand always disconnect the battery.
Camshaft rotation can be verified by: Remove oil filler cap and check if camshaft is visible.
- Remove valve cover and directly observe camshaft.
- Remove distributor cap and check for rotor rotation (the rotor is driven by the camshaft)
- Remove upper timing belt cover and check camshaft pulley rotation and belt integrity.
Other Indications the Timing Belt may be broken. No ignition spark.
- Very low compression (<15 psi) on all cylinders. Due to the low compression the following
additional symptoms may be present. While attempting to start the car, the battery strength remains high for an unusually long length of
time.
- The sound of the engine while attempting to restart will be different than normal. Instead of the
usual rhythmic "Rir.. .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no
detectable rhythm.
NOTE: For an experienced technician this unique sound will often be the initial symptom that leads
to a more in-depth check of the
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1443
timing belt.
OTHER RELATED PROBLEMS
The Timing Belt has Jumped Teeth If the belt is excessively worn, loose, or missing teeth it is possible for the belt to jump teeth on the
crankshaft.
- A belt which is off by just one tooth will cause an engine to run very poorly or not run at all.
- A belt which is off by more than one tooth will generally prevent the engine from starting.
- To verify the problem, remove the timing belt covers and check the crankshaft and camshaft
alignment marks.
The Camshaft is Seized
- A seized camshaft will produce the same symptoms as a broken timing belt.
WARNING: Rotating the camshaft with the timing belt removed on an interference engine can
result in additional valve damage.
INTERFERENCE/FREE RUNNING
Interference - Upon reaching Top Dead Center a piston will impact a valve which is fully open. This
situation occurs when the timing belt breaks and a valve is left fully open while the pistons continue
to operate.
NOTE: This engine is an Interference design.
Free Running - The engine has been designed such that should the timing belt break there will still
be clearance between a fully open valve and a piston at TDC.
Valve Damage - Interference engines will generally bend intake or exhaust valves when a timing
belt is broken. When a timing belt breaks the rotational momentum of the camshaft will cause
several valves to open and close out of sequence with the movement of the pistons.
Any valve which is left open when the associated piston reaches TDC will be struck and bent. Bent
valves will generally stick in a partially open position, resulting in a loss of vacuum and
compression on that cylinder.
If a timing belt breaks during normal city or highway driving the probability that an interference
engine will bend at least one valve is very high.
NOTE: If a timing belt breaks, an interference type engine will not always bend or damage valves.
If the timing belt breaks during start-up with camshaft remaining in a position where no valve is fully
open there will be no valve damage.
Free running engines will generally not bend or damage valves when a timing belt is broken.
However the design clearance between a fully open valve and a piston at TDC may be quite small
(<0.020 inches) . A build up of carbon on top of the piston in conjunction with improperly adjusted
valve clearances can result in a free running engine bending valves when the timing belt breaks.
VERIFYING VALVE DAMAGE
Install a new timing belt with the camshaft and crankshaft aligned properly and attempt to start the
engine. If the engine starts and runs smoothly with steady high vacuum levels, the valves are not
damaged.
WARNING: Rotating the camshaft with the timing belt removed on an interference engine can
result in additional valve damage.
If the engine fails to start or runs roughly with the manifold vacuum reading rapidly oscillating over
a 4-6 inch range there may be valve damage.
NOTE: Verify that the crankshaft and camshaft are aligned properly. A timing belt which is off Dust
one tooth may produce similar
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1444
performance symptoms.
Remove the valve cover and inspect the valve clearances. A valve which is bent will be stuck in the
open position or will have an excessively larger clearance.
Perform a compression check or a cylinder leak down check. Cylinders with bent valves will have
very low compression (<50.0 psi) and will not hold pressure.
If valve damage is detected the cylinder head will have to be removed and the damaged valves
replaced. Also inspect top of the pistons for damage.
Initial Preparations
INITIAL PREPARATIONS
Disconnect Battery
When working near or around the crankshaft/camshaft pulleys, accidentally engaging the starter
can result in serious personal injury and major engine damage.
The negative battery terminal should be disconnected prior to commencing work and should not be
reconnected until the timing belt is re-installed and the engine is ready to start.
Remove Front Tire
Access to lower timing belt components can be gained by removing the associated front tire and
working through the wheel well.
Fender Covers
Fender covers will prevent damage to the vehicles finish while performing the job.
Positioning Crankshaft to Number 1 TDC
POSITIONING CRANKSHAFT TO #1 TDC, Compression
NOTE: If the timing belt is broken, pre-position only the crankshaft and ignore references in this
article to compression stroke, camshaft, and distributor position. Rotating the camshaft with a
broken timing belt may damage the valves.
WHY
Timing belt installation alignment marks correspond to the crankshaft positioned at #1 Top Dead
Center (TDC), during the compression stroke. Moving the crankshaft to this point prior to removing
the belt allows you to verify the original alignment of the crankshaft and camshaft. This also
reduces crank/cam pulley movement once the belt is removed which helps to minimize any
possible confusion.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1445
The alignment marks may be dirty and difficult to locate. Pre-positioning the crankshaft will make it
easier to locate the marks.
HOW
- Remove the distributor cap and observe the position of the rotor.
- Using the crankshaft bolt, rotate the crankshaft until the distributor rotor is nearly pointing towards
the #1 cylinder position.
- Then slowly rotate the crankshaft until the timing indicator is pointing at the "0"/TDC degree mark.
NOTE: Remember that the crankshaft rotates twice for every rotation of the camshaft. The rotor
must be pointing towards #1 cylinder terminal when the timing mark reaches 0 degrees.
Removal and Installation Tips and Hints (Maintenance)
TIMING BELT REMOVAL
- Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be
removed to replace the timing belt it would be convenient to have any necessary replacement belts
on hand should any the drive belts show excessive wear.
- After the timing belt covers are removed, verify the camshaft and crankshaft are properly aligned.
- Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets
or covers could allow moisture and debris to enter the covers and damage the belt.
NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing
belt or between the belt and the pulley, resulting in the belt skipping teeth.
- When removing the engine mount, Slightly raise the engine with a floor jack. This will take the
weight of the engine off of engine mount bolts and will ease in removal.
CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of
wood or other soft material to prevent puncturing the oil pan.
TIMING BELT INSTALLATION
- When positioning or removing the camshaft and crankshaft pulleys, do not grasp the teeth of the
pulleys with pliers or any other metal object.
CAUTION: Any nick or burr left on the pulleys may result in premature belt failure.
- When installing the timing belt: Do not use any device to pry the belt over a pulley
- Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on.
- Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack
is left on the opposite side, when the tensioner is released the pulleys will turn and the belt
alignment will be incorrect.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1446
- After installing and tensioning the belt, recheck the alignment of the camshafts and crankshaft.
Removal and Installation Tips and Hints (Broken Belt)
TIMING BELT REMOVAL
- Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be
removed to replace the timing belt it would be convenient to have any necessary replacement belts
on hand should any the drive belts show excessive wear.
- After the timing belt covers are removed, align the camshaft and crankshaft.
1. Position the crankshaft to a safe position (approaching #1 Top Dead Center (TDC) with no
cylinder at or near top dead center) 2. Align the camshaft with its timing marks. 3. Rotate the
crankshaft to #1 TDC
WARNING: Valve damage will occur if any cylinder reaches Top Dead Center, while an associated
valve is at or near its fully open position.
NOTES When positioning the camshaft or crankshaft always rotate the shafts slowly and in small
increments, while frequently stopping to observe the relationship of the valves and pistons.
- With the spark plugs removed the crankshaft should rotate easily. If any resistance is felt,
immediately stop and verify that a piston is not striking a valve.
- Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets
or covers could allow moisture and debris to enter the covers and damage the belt.
NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing
belt or between the belt and the pulley, resulting in the belt skipping teeth.
- When removing the engine mount, slightly raise the engine with a floor jack. This will take the
weight of the engine off of engine mount bolts and will ease in removal.
CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of
wood or other soft material to prevent puncturing the oil pan.
INSPECTION
- Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or
damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt
mating surface will require the pulley to be replaced.
- Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp,
causing the pulleys or belts to rub against the inside of the cover.
- Inspect the tensioner/idler/water-pump pulleys for wobble or looseness. The pulleys should spin
freely with no rough spots or lateral (side-to-side) movement.
- Inspect the tensioner/idler/water pump pulley surfaces. They should be clean and free of nicks
and burrs. If any damage is noted the pulleys should be replaced.
- Inspect the water pump for signs of leakage, replace if necessary.
- Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage
should be replaced.
CAUTION: Oil leakage will damage the new timing belt.
TIMING BELT INSTALLATION
- When positioning or moving the camshaft and crankshaft pulleys, do not grasp the teeth of the
pulleys with pliers or any other metal object.
CAUTION: Any nick or burr left on the pulleys may result in premature belt failure.
- When installing the timing belt: Do not use any device to pry the belt over a pulley
- Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1447
- Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack
is left on the opposite side, when the tensioner is released the pulleys will turn and the belt
alignment will be incorrect.
- After installing and tensioning the belt, recheck the alignment of the camshafts and crankshafts.
Checking Engine Vacuum
CHECKING ENGINE VACUUM
Manifold vacuum readings (taken at a vacuum port downstream of the throttle plate) should be
steady and smooth. If valve damage has occurred the needle will rapidly fluctuate back and forth.
NOTE: Prior to checking vacuum, the ignition timing should be checked and adjusted. Ignition
timing will affect the vacuum levels.
To verify valve, perform a compression check or leak down check on all cylinders. Cylinders with
damaged valves will not develop compression and will not hold pressure.
If valve damage is detected the cylinder head will need to be removed.
Recommended Parts
RECOMMENDED PARTS
- New Timing Belt - Compare length, width, and shape of teeth to the old belt. They should match
exactly.
OPTIONAL, PENDING INSPECTION
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Fundamentals and Basics > General Information > Page 1448
- Water Pump - Replacing the water pump requires removing the timing belt. A thorough
examination of the water pump while the timing belt is removed is highly recommended.
- Gasket Sealant - When removing the timing belt covers the gaskets may come unglued from the
covers.
- Camshaft and Crankshaft Seals - These seals are located behind the timing belt gears. Leakage
from these seals can rapidly deteriorate a new timing belt.
- Drive Belts - Drive belt removal is required to access the timing belt.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Locations
Fuel Pressure Test Port: Locations
System not equipped with fuel pressure test port. (To test fuel pressure tee into system with
adapter.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Adjustments
Air/Fuel Mixture: Adjustments
CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw.
Never attempt to adjust idle mixture using this screw!
Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not
adjustable.
If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE
Computers and Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
IDLE SPEED
Idle speed adjustment is electronically controlled by the Automatic Idle Speed (AIS) Motor and is
not adjustable. For diagnosis of incorrect idle speed, refer to COMPUTERIZED ENGINE
CONTROLS.
IDLE SPEED
Automatic .............................................................................................................................................
.................................................................. 800 RPM Manual ..............................................................
...................................................................................................................................................... 800
RPM
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > Page 1460
Idle Speed: Testing and Inspection
1. Remove air cleaner assembly, then plug heated air door vacuum hose.
2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan
cycles ON and OFF at least once. STOP engine.
3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and
ensure basic timing is set to 12° BTDC.
4. STOP engine and reconnect coolant temperature sensor wire.
5. Disconnect PCV valve hose from intake manifold nipple.
6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV
nipple.
7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1
minute.
8. Using scanner, place read/hold switch in read position and depress ATM button until code 70
appears.
9. Place read/hold switch to hold position, then the following should occur: a.
AIS motor will fully close.
b. Idle spark advance will become fixed.
c. Idle fuel will become enriched.
d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example,
display 95 equals 95 x 10 which indicates 950 rpm.
10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is
satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE
PROCEDURES. Retest minimum air flow after throttle body cleaning.
11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install
PCV valve hose.
12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door
vacuum hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > Page 1461
Idle Speed: Adjustments
CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw.
Never attempt to adjust idle speed using this screw, unless directed to do so in a service
procedure.
Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air
Control (IAC) motor, and is not adjustable.
If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if
deposits are visible. Perform Minimum Idle Air Flow Test if applicable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
1. Loosen gas cap and allow tank pressure to release.
2. Remove wiring harness connector from any injector, then ground one injector terminal.
3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery
for approximately 10 seconds and release system pressure.
4. Remove jumper wires and service fuel system as required.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications > Cylinder Location
1988-1996 3.0L (182)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications > Cylinder Location > Page 1470
Distributor Cap From The Top - Includes Connections Inside The Cap. (Round Terminals Are Plug
Wire Connections On The Top Of The Cap.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Number One Cylinder: Locations
1988-1996 3.0L (182)
3.0L Except Stealth
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Timing Marks and Indicators > System Information > Diagrams
Timing Marks and Indicators: Diagrams
TIMING MARK 3.0L
Timing Scale Above Crank Pulley--Viewed From Front Of Car
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Specifications
Ignition Cable: Specifications
Minimum
..................................................................................................................................................... 250
ohms per inch (3,000 ohms per foot)
Maximum
............................................................................................................................................... 1,000
ohms per inch (12,000 ohms per foot)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Component Information > Specifications
Distributor: Specifications
Distributer Adapter ...............................................................................................................................
.......................................... 14 Nm (120 in lbs) Distributer Housing Bolt .............................................
.................................................................................................................... 15 Nm (130 in lbs)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Component Information > Specifications > Page 1484
Distributor: Locations
Distributor Hold-Down
The Optical Distributor is located at the back of the engine, behind the right-hand cylinder head.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Component Information > Specifications > Page 1485
Distributor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap Specifications
Spark Plug: Specifications Gap Specifications
Refer to the Vehicle Emission Control Information (VECI) label, (under hood).
If label is gone, or not readable, verify system and use the following specification.
Plug Gap ..............................................................................................................................................
.................... 0.9 to 1.1 mm (0.039 to 0.044 in)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap Specifications > Page 1490
Spark Plug: Specifications Tightening Specifications
Spark Plug Torque ...............................................................................................................................
...................................................... 28 Nm (20 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
SERVICE SPECIFICATIONS
Compression pressure .....................................................................................................................
840 kPa (178 psi) +/- 100 kPa (14 psi) @ 250-400 rpm Maximum variation .......................................
..............................................................................................................................................................
.... 25% Manifold vacuum ....................................................................................................................
........................................................... 520 mmHg (20 in.Hg.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 1494
Compression Check: Testing and Inspection
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the
throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure
gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the
compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
NOTE: Correct engine compression pressures should be 178 psi +/- 14 psi, Maximum cylinder
deviation 25%
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all
times.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 1498
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters. No provision for adjustment is provided.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem
Water Pump: Testing and Inspection Verifying Water Pump Problem
VERIFYING WATER PUMP PROBLEM
Check for Loose Water Pump Pulley
As the pump shaft seals and bearings wear with age the pulley/shaft may develop a wobble or
lateral runout.
With the engine off and the key removed from the ignition, attempt to move the pulley from side to
side and back and forth. There should be no detectable movement. The pulley should turn
smoothly, with no rough spots.
The water pump should be replaced if any pulley wobble is detected. If the water pump is not
replaced the pump shaft may eventually seize or break.
NOTE: Incorrect belt tension (too tight) may cause premature wear of the bearings and seals.
WARNING: Never remove a radiator cap while the engine is hot. Severe personal injury may result.
Inspect for Leakage
1. With the engine "OFF" and cold:
- Check coolant level and refill if necessary.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem > Page 1503
- Inspect the water pump for leakage. Closely check the following areas: -
Inspection (weep) hole.
- Pump shaft.
- Gasket.
2. Pressurize the cooling system with a pressure tester and again check for leaks. Do not exceed
the rated pressure of the radiator cap.
NOTE: If any leaks are found, verify that they are not originating from a component near or above
the water pump (i.e. thermostat, loose radiator hoses, intake gasket, engine coolant temperature
sensor)
CAUTION: When finished, immediately re-install the radiator cap.
3. If no leaks are found, start and warm the engine until the thermostat opens. Stop the engine and
check for fresh leakage around the water pump
shaft.
NOTE: Occasionally water pumps will only leak around the shaft seals while the shaft is rotating.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem > Page 1504
Water Pump: Testing and Inspection After Repairs Operational Check
COOLING SYSTEM OPERATIONAL CHECK
IMPORTANT: Always verify the operation of the thermostat and cooling fan prior to driving the
vehicle after a cooling system repair.
HOW
- With the cooling system filled with coolant and the radiator cap installed, start the engine and
allow the coolant to warm up.
- The upper radiator hose should remain cool to the touch until the coolant within the engine block
and head has reached the thermostat opening temperature.
The thermostat opening should be indicated by a rapid warm up of the upper radiator hose.
- If upper hose gradually warms up, the thermostat may be stuck open (assuming the engine is
started cold)
- If the coolant temperature reaches the normal operating temperature (as indicated by the
temperature gauge) before the upper hose becomes warm, the engine should be turned off, and
the cooling system allowed to cool down. The thermostat may be stuck closed and should be
removed and tested.
WARNING: Never remove the radiator cap, or disconnect a coolant hose on a warm engine. A
warm cooling system may contain a large amount of stored energy in the form of steam and high
pressure, which could seriously injure you.
- If the thermostat opened properly, continue to allow the cooling system to warm up. As the
coolant temperature reaches its maximum operating temperature the electrical cooling fan should
energize. Verify the fan energizes and de-energizes.
WHY
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem > Page 1505
Thermostat Closed, Cold Engine - With the thermostat closed, coolant flow through the radiator is
blocked forcing the coolant to re-circulate through the block and head. This allows for a rapid warm
up. During this time there should be little or no coolant flow through the upper radiator hose.
Thermostat Open, Warm Engine - Once the coolant has reached normal operating temperature,
the thermostat begins to open, allowing coolant flow through the upper hose and into the radiator.
The thermostat will continue to regulate the amount of coolant flow to the radiator to maintain a
"Minimum" operating temperature.
Electric Cooling Fan Operation
The cooling fan ground circuit is controlled by the cooling fan relay. The relay opens and closes to
supply or remove ground (-) from the fan. With the ignition key "ON" positive (+) voltage is
constantly supplied to the motor.
The relay is controlled by the cooling fan temperature switch. The switch supplies the ground path
for the operating coil within the cooling fan relay.
When the coolant temperature reaches the maximum set point, the coolant switch closes and
grounds the operating coil within the fan relay. The coil then closes the relay contacts, supplying
ground to the fan motor.
When the coolant temperature fails to the lower set point, the coolant switch opens, removing
ground from the fan relay. The fan relay then opens and de-energizes the cooling fan.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Verifying Water Pump Problem > Page 1506
Water Pump: Testing and Inspection After Repairs Leak Check
AFTER REPAIRS LEAK CHECK
PURPOSE
Initially fill the cooling system and check for leaks prior to starting the engine and bleeding the
system. Although the system will not be completely full, any leaks which are detected may be fixed
before the engine and cooling system are hot.
NOTE: It is much easier to repair a leak on a cold engine than on a hot engine.
HOW
- Fill the cooling system until the radiator is full.
- Apply pressure to the system with a pressure tester.
- Carefully check for leaks around: All hoses and clamps.
- Water pump sealing surfaces.
- Any cooling system component which was removed or replaced.
- If no leaks are detected continue with the fill and bleed procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Page 1507
Water Pump: Service and Repair
Water Pump And Coolant Tube
Fig. 32 Water Pump Removal & Installation
NOTE: The water pump bolts directly to the engine block, using a gasket for pump-to-block sealing,
Fig. 32. The water pump is driven by the timing belt and is serviced as a unit.
1. Disconnect battery ground cable.
Fig. 13 Crankshaft Pulley Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Page 1508
2. Remove crankshaft drive pulleys and torsional damper, Fig. 13.
Fig. 14 Right Engine Mount & Bracket
3. Place a jack under engine to support and slightly raise engine, then remove engine mount
bracket, Fig. 14.
Fig. 15 Timing Belt Cover
4. Remove timing belt cover, Fig. 15, then mark belt running direction for reinstallation. 5. Loosen
timing belt tensioner, then remove belt and crankshaft sprocket flange shield. 6. Drain cooling
system. 7. Remove water pump mounting bolts. 8. Separate water pump from water inlet pipe Fig.
32, then remove water pump. 9. Reverse procedure to install, noting the following:
a. Use a new O-ring on water inlet pipe. b. Torque water pump mounting bolts to 27 Nm (20 ft.
lbs.). c. Refer to Engine/Timing Components/Timing Belt/Service and Repair for timing belt
installation and tensioning procedure. See: Timing
Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Page 1509
Water Pump: Tools and Equipment
RECOMMENDED TOOLS
- Drip pan - For draining coolant.
- Gasket scraper.
- Torque Wrenches: Low Range (0-50 ft-lb) for covers and brackets.
- High Range (0-150 ft-lb) for crankshaft pulley bolt.
- Full set of Metric sockets and wrenches.
Timing Belt Removal Is Required Timing light (for measuring timing before and after).
- Vacuum gauge (for measuring engine vacuum levels before and after).
Crankshaft Pulley Removal
Crankshaft Holding Tool MD998784 (used in conjunction with an old drive belt), or an air powered
impact gun (for removing the crankshaft bolt).
Timing Belt Tensioner Release
- Large flat blade screw driver (for moving timing belt tensioner).
- Fender covers.
OPTIONAL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and
Inspection > Page 1510
- Radiator hose removal tool.
- Cooling system pressure tester.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations
Water Pump: Fundamentals and Basics Initial Preparations
INITIAL PREPARATIONS
Disconnect Battery
When working near or around the cooling fan or drive belts, accidentally engaging the starter or
cooling fan can result in serious personal injury.
The negative battery terminal should be disconnected prior to commencing work and should not be
reconnected until after the water pump is installed and the engine is ready to restart.
Fender Covers
Fender covers will prevent damage to the vehicles finish while performing the job.
Coolant Drip Pan
Pre-position a drip pan under the vehicle to prevent any incidental spills
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1513
Water Pump: Fundamentals and Basics Removal Tips and Hints
WATER PUMP REMOVAL TIPS AND HINTS
FROZEN AND BROKEN BOLTS
Frozen and broken bolts are often a major problem when removing water pumps. Coolant can seep
into the bolt holes resulting in corrosion and frozen bolts. Prior to starting the job, spray all water
pump retaining bolts with a penetrating oil.
Upon removal, any bolt or nut which shows signs of corrosion should be replaced. The threads of
the associated bolt hole should be re-tapped or chased.
Inspect the coolant hoses, drive belts, and associated pulleys. Since these components will need to
be removed to replace the timing belt it would be convenient/time saving to have any necessary
replacement parts on hand prior to removing the pump.
COOLANT HOSES
Inspect the hoses for the following: Cracks, especially near the hose clamps.
- Swelling, look for areas of the hose that appear unnaturally bulged outwards.
NOTE: This is often caused by improper removal techniques, see Hose Removal in this article.
- Oil contamination, soft spots, oil contamination breaks down the structure of the rubber and
significantly weakens the hose.
NOTE: The oil leak should be fixed prior to replacing the hose.
- Hard or brittle hoses, as the hoses age the rubber looses its resiliency and becomes brittle. The
hoses need to be able to flex to compensate for the movement of the engine.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1514
DRIVE BELTS
Small cracks that run across that run across the ribbed surface of the belt from rib to rib , are
considered normal, These are not reasons to replace the belt.
If chunks of belt material are missing between the cracks, the belt should be replaced.
Cracks running along the rib (not across) are not normal. Any belts with cracks running along the
rib should be replaced.
Replace the belt if it has excessive wear, frayed cords or severe glazing.
Drive Pulleys
- Verify the pulleys have no side to side wobble, and rotate freely. Replace if necessary.
- Verify the pulleys are properly aligned. Adjust or replace as necessary.
Belt Removal
Do not attempt to bump the drive belts off with the starter. This practice can damage the belt,
pulley, and technician. Removing the belt by relaxing the tension will allow you to correctly adjust
the tension when installing the belt.
DRIP PAN
Prior to removing any hose or the water pump, place a large drip pan under the engine. Although
the coolant may be drained from the radiator, there is still a large amount of residual coolant
trapped in the hoses and water pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1515
HOSE REMOVAL
Prior to pulling the hose from the fitting, rotate/twist the hose on the fitting to break the grip of any
corrosion present.
If the hose is to be replaced, it may be quicker to cut hose from the fitting.
CAUTION: When cutting the hose be careful not to damage the fitting.
A radiator hose removal tool may help free up stubborn hoses.
CAUTION: Do not use any device to pry the hose off of the fitting.
- If at any time a tearing or ripping sound is heard (though the hose appears fine) the hose should
be replaced. The sound is coming from the internal reinforcing fibers embedded in the hose. Once
the fibers have been broken the hose will be subject to swelling and rupture when pressure is
applied.
WATER PUMP REMOVAL
After removing the retaining bolts the water pump may still be stuck to the engine. The original
gasket sealant may cause the pump to firmly stick to engine. A few soft blows from a rubber mallet
or block of wood will generally loosen the pump.
CAUTION: Verify that ALL of the retaining bolts are removed.
- Do not pry between the pump and the gasket. This may damage the pump sealing surface.
- Upon breaking the seal, a large amount of coolant trapped in the block will generally pour out
from the water pump opening. Be sure to have a drip pan prepositioned.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1516
Water Pump: Fundamentals and Basics Gasket Removal and Inspection
GASKET REMOVAL
- Remove all traces of the old gasket material. It only takes a very small amount of left over
material to cause the new gasket to leak.
- Never reuse gaskets. After a gasket has been initially installed and removed it will no longer be
able to compensate for the varying expansion rates of the water pump and block. An old gasket
may seal initially but as the engine heats up cools down, the old gasket will be prone to leakage.
- When removing the gasket with a gasket scraper, be very careful not to gouge the sealing
surface. Very small scratches in the sealing surface are likely to leak.
HINT: Always sharpen your gasket scraper prior to starting a job. A dull scraper is more likely to
slip and gouge the sealing surface.
- If you are using a buffing wheel to clean the gasket surface, be very careful not to burn the
surface.
CAUTION: Buffing wheels can rapidly remove metal from the sealing surface, be very careful and
check your work frequently.
INSPECTION
- Verify the gasket sealing surfaces are free of all gasket material, dirt, gouges, and contaminants
(such as coolant or oil)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1517
Water Pump: Fundamentals and Basics Installation Tips and Hints
WATER PUMP INSTALLATION TIPS AND HINTS
- Compare the old pump to the new pump and verify: Shaft lengths match exactly.
- Retaining bolt holes match exactly.
- Prior to applying the sealant to the gasket and pump, practice installing the pump to the engine. If
any problems are encountered they will be easier to solve without the silicone applied.
- Verify the retaining bolts and bolt holes have clean threads. Re-tap or chase the threads as
necessary.
- To simply the gasket installation process and minimize errors, install the gasket as follows:
1. Verify the gasket is correct. 2. Apply the sealant to the pump sealing surface and the gasket
inner surface. Apply only a light film of sealant to the sealing surfaces.
CAUTION: Excess sealant will squeeze out on the inside of the pump and may block the radiator or
heater core coolant passages.
3. Install two retaining bolts through the pump.
NOTE: This will help maintain the correct alignment of gasket in the next step.
4. While holding the bolts, place the gasket over the bolts and onto the pump sealing surface. 5.
Install the pump and gasket onto the engine.
- Do not over tighten the retaining bolts, use a torque wrench to properly tighten the bolts to the
correct specification.
CAUTION: Water pump retaining bolts may be easily broken or stripped, do not tighten the
retaining bolts with an air wrench or impact gun.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1518
- When tightening hose clamps: Position the hose squarely on the fitting.
- Verify the hose clamp is clear of the retaining rim on the fitting. Do not over tighten the clamps.
- While working on the cooling system it is a good habit to clean the radiator and A/C condenser
fins of bugs and dirt. This build up of debris can seriously reduce the cooling ability of the system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1519
Water Pump: Fundamentals and Basics Recommended Parts
RECOMMENDED PARTS
- New water pump, gasket and O-ring.
- RTV sealant (for sealing water pump gasket, do not apply to O-ring).
NOTE: Use only non-volatile oxygen sensor safe RTV sealant. This should be clearly indicated on
the package.
- Engine Coolant: Manual transmission - 8.9 qts. Automatic transmission- 8.8 qts
NOTE: For optimum performance, use 50/50 mixture of high quality ethylene glycol coolant and
water.
- Intake gasket set (if intake manifold removal is necessary)
NOTE: A coolant pipe runs from the back of the water pump, under the intake manifold and to the
rear of the engine. This pipe has may leak and should be inspected. Replacing the pipe requires
removing the intake manifold.
OPTIONAL, PENDING INSPECTION
- Timing belt
- Radiator hoses.
- Bypass hose.
- Drive belts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Engine - Coolant Recommendations
Coolant: Technical Service Bulletins Engine - Coolant Recommendations
NO: 07-03-97
GROUP: Cooling
DATE: May 9, 1997
SUBJECT: Engine Coolant Usage
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26,
1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993
TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE
BULLETIN IS REVISED.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1997 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/
Power Ram/Power Ram Cab & Chassis
1989 - 1993 (AG) Daytona
1989 (AH) Lancer/LeBaron GTS
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1997 (AN) Dakota
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 1997 (BR) Ram Truck
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (European Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1989 - 1992 (MJ) Comanche
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1997 (PR) Prowler
1992 - 1997 (SR) Viper/Viper Coupe
1997 (TJ) Wrangler
1989 - 1997 (XJ) Cherokee
1989 - 1995 (YJ) Wrangler
1993 - 1997 (ZJ) Grand Cherokee
DISCUSSION:
Some owners have expressed interest in using engine coolants made with propylene glycol instead
of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals.
Based on recent test data, most owners should not experience significant effects on cooling system
performance when using propylene glycol based coolant. The use of national brand propylene
glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170
(or equivalent ASTM D5216) is acceptable for Chrysler built vehicles.
NOTE:
ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A
SUITABLE ENGINE COOLANT.
However, owners should be discouraged from changing their engine coolant prior to the regularly
scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the
risk of environmental exposure.
Sufficient freeze protection for the region should be maintained. However, do not use more than a
55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a
higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the
temperatures for your region fall below this, use ethylene glycol coolant.
Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in
cooling performance. If this is noticed, the system should be changed back to ethylene glycol
coolant.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Engine - Coolant Recommendations > Page 1525
The two types of coolant should not be mixed. The standard testers for measuring freeze protection
will not provide an accurate reading when this occurs. If the cooling system is changed to
propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling
system flush procedure. The freeze protection of propylene glycol cannot be measured with a
standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol
is the preferred test tool.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Engine - Coolant Recommendations > Page 1526
Coolant: Technical Service Bulletins Engine Coolant - Recycling Recommendations
SUBJECT: Engine Coolant Recycling NO.:
07-03-90
GROUP: COOLING
DATE: Dec. 21, 1990
MODELS:
All Domestic & Import Vehicles
DISCUSSION:
A number of systems are being marketed to "recycle" or "reconstitute" used ethylene glycol
antifreeze/coolant in the dealership. Some of the systems have been advertised as producing a
recycled antifreeze "as good as" original and suggest the recycled product is suitable for use in
Chrysler Corporation vehicles.
Tests, so far, indicate most of these systems merely remove suspended solids from the used
antifreeze/coolant through the use of various size filters. These systems do not remove glycol
degradation products, or dissolved solids, which can cause water pump seal wear.
These systems use a universal "reinhibitor package". The "reinhibitor package" can not restore
every type antifreeze/coolant inhibitor system to a like new condition.
Tests results indicate these "recycled" products do not consistently provide the protection required
in Chrysler Corporation engines and cooling systems.
The use of these "reconstituted" antifreeze/coolants is not authorized in the performance of any
repair covered under the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Page 1527
Coolant: Specifications
COOLING SYSTEM CAPACITY
1988-89 Caravan / Voyager / Grand Caravan / Grand Voyager
2.5L Engine .........................................................................................................................................
........................................................ 8.1 L (8.5 qts) 3.0L Engine
without rear heater ...............................................................................................................................
............................................... 9.5 L (10.0 qts) with rear heater ..........................................................
....................................................................................................................... 10.5 L (11.0 qts)
NOTES:
- Includes 0.47 L (1.0 pt) for the heater and coolant reserve bottle.
- Includes 0.95 L (1.0 qt) for rear heater systems, if equipped.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Page 1528
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Locations
Water Pump And Coolant Tube
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1537
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1538
Radiator Cooling Fan Motor: Electrical Diagrams
A/C & Heater Wiring Circuit (Part 1 Of 2)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1539
A/C & Heater Wiring Circuit (Part 2 Of 2)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 1540
Radiator Cooling Fan Motor: Description and Operation
Electric Fan Motor (Typical).
RADIATOR FAN CONTROL
Fan control is accomplished two ways. The fan always runs when the air conditioning compressor
clutch is engaged. In addition to this control, the fan is turned on by the temperature of the coolant
which is sensed by the coolant temperature sensor which sends the message to the on-board
computer. The computer turns on the fan through the fan relay.
Switching through the on-board computer provides fan control for the following conditions.
1. The fan will not run during cranking until the engine starts no matter what the coolant
temperature is.
2. Fan will always run when the air conditioning clutch is engaged.
3. On non-air conditioned vehicles or with air conditioning off the fan will run at vehicle speeds
above about 40 mph only if coolant temperature
reaches 110°C (230°F) and will turn off when the temperature drops to 1O4°C (220°F). At speeds
below 40 mph the fan switches on at 99°C (210 °F) and off at 93°C (2OO°F).
4. There also is included a method to help prevent "steaming" (water vapor evaporated by hot
water circulating through the radiator evaporating
moisture on the outside of the radiator - and when there is no ram air to blow it under the vehicle)
the fan will run only below 16°C (60°F) ambient, from 38°C (100°F) to 97°C (195°F) coolant
temperature. only at idle, and zero vehicle speed and then only for three minutes.
TEMPERATURE GAGE INDICATION
At idle with Air Conditioning off the temperature gage will rise slowly to about 5/8 gauge travel, the
fan will come on and the gauge will quickly drop to about 1/2 gauge travel - this is normal.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Testing and Inspection > Testing Procedures
Radiator Cooling Fan Motor: Testing and Inspection Testing Procedures
Electric Fan Motor (Typical).
ELECTRIC FAN MOTOR TEST PROCEDURE
To check out the electric fan motor, disconnect the fan motor wire connector and connect it with
#14 gage wires to a good 12-volt battery observing correct polarity per figure. If the fan runs
normally, the motor is functioning properly. If not, replace motor. If the motor is noticeably
overheated (i.e.; wire insulation melted, motor charred) the system voltage may be too high. Check
charging system.
SMEC (Engine Controller) 60-Way Connector From Terminal End
RADIATOR FAN MOTOR CONTROL TEST PROCEDURE (Fan Relay and SMEC Operated)
Equipment Required ^
Diagnostic Tool C-4850 or equivalent
^ Volt/Ohm Meter
^ Wiring Diagrams.
1. Bring the engine to normal running temperature.
2. Check wiring connector in C25, C9. and C26 for proper engagement, see Wiring Diagrams.
3. Using a diagnostic tool, plugged into the diagnostic connector rearward of the battery, check the
On-Board Diagnostics (OBD) in the Single
Module Engine Control (SMEC) for fault codes.
4. If fault code 88-12-35-55 is detected. proceed to Step 5.
5. With the ignition switch in the run position, test for battery voltage at single pin connector at the
fan relay.
^ Voltage reading OK. proceed to Step 6a.
^ Voltage at 0-1 volt, proceed to Step 6b.
6a With the ignition OFF, disconnect the 60-way connector from the SMEC (outboard of battery)
and return the ignition to the RUN position. Test
for battery voltage at cavity 31 of the 60-way connector. ^
Voltage reading OK and female terminal is not damaged, replace the SMEC.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Testing and Inspection > Testing Procedures > Page 1543
^ Voltage reading 0. repair open or short in C27 circuit.
6b With the ignition off, disconnect the 60-way connector from the SMEC (outboard of battery) and
return the ignition to the RUN position. Test for
battery voltage at the single pin connector at the fan relay. ^
Voltage reading OK. replace the SMEC.
^ Voltage reading 0-1 volt. proceed to Step 7.
7. With ignition in the run position. test for battery voltage at the blue wire (C27) in the 3-way
connector of the fan relay.
^ Voltage reading OK. replace the fan relay.
^ Voltage reading 0. repair open or short, in C27 circuit
8. Turn ignition off, connect the 60-way connector at the SMEC, and test the system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Testing and Inspection > Testing Procedures > Page 1544
Radiator Cooling Fan Motor: Testing and Inspection Motor Circuit Testing
Refer to SCHEMATIC DIAGRAMS/ELECTRICAL AND ELECTRONIC DIAGRAMS for wiring
diagrams when performing the following procedure.
1. Check engine and bring to normal operating temperature.
2. Check fan motor electrical connector for proper engagement.
3. Connect diagnostic tool to connector, if fault code 88-12-35-55 is displayed, proceed to step 4.
4. With ignition switch in run position, test battery voltage at single pin connector at fan relay.
Fig. 25 SBEC 60-way connector
5. If voltage reading is normal: a. With ignition off, disconnect 60 way connector from single board
engine control (SBEC), and return ignition to run position. Test battery
voltage at cavity 31 of 60-way connector.
b. If voltage reading okay and female terminal is not damaged, replace the SBEC. If voltage
reading is 0, repair open or short in circuit C27.
6. If voltage reading is 0-1 volt: a. With ignition off, disconnect 60-way connector from SBEC, and
return ignition to run position. Test battery voltage at single pin connector at
fan relay.
b. If voltage reading is okay, replace SBEC. c. If voltage is 0-1, test voltage at blue wire in 3-way
connector of fan relay. d. If voltage reading okay, replace fan relay. If voltage reading 0, repair
open or short in circuit C27.
7. Turn ignition off, connect 60-way connector at SBEC and test system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Testing and Inspection > Testing Procedures > Page 1545
Radiator Cooling Fan Motor: Testing and Inspection Radiator Fan Control
Electric Fan Motor (Typical).
RADIATOR FAN CONTROL
Fan control is accomplished two ways. The fan always runs when the air conditioning compressor
clutch is engaged. In addition to this control, the fan is turned on by the temperature of the coolant
which is sensed by the coolant temperature sensor which sends the message to the on-board
computer. The computer turns on the fan through the fan relay.
Switching through the on-board computer provides fan control for the following conditions.
1. The fan will not run during cranking until the engine starts no matter what the coolant
temperature is.
2. Fan will always run when the air conditioning clutch is engaged.
3. On non-air conditioned vehicles or with air conditioning off the fan will run at vehicle speeds
above about 40 mph only if coolant temperature
reaches 110°C (230°F) and will turn off when the temperature drops to 1O4°C (220°F). At speeds
below 40 mph the fan switches on at 99°C (210 °F) and off at 93°C (2OO°F).
4. There also is included a method to help prevent "steaming" (water vapor evaporated by hot
water circulating through the radiator evaporating
moisture on the outside of the radiator - and when there is no ram air to blow it under the vehicle)
the fan will run only below 16°C (60°F) ambient, from 38°C (100°F) to 97°C (195°F) coolant
temperature. only at idle, and zero vehicle speed and then only for three minutes.
TEMPERATURE GAGE INDICATION
At idle with Air Conditioning off the temperature gage will rise slowly to about 5/8 gauge travel, the
fan will come on and the gauge will quickly drop to about 1/2 gauge travel - this is normal.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Testing and Inspection > Page 1546
Radiator Cooling Fan Motor: Service and Repair
There are no repairs to be made to the fan. If the fan is cracked, warped or otherwise damaged, it
must be replaced as an assembly.
1. Disconnect battery ground cable and electrical connector from fan motor.
2. Remove shroud clips if equipped and support bolts, nuts and washers.
3. Remove fan, motor and shroud or support as an assembly from radiator support.
4. Remove fan from motor shaft by supporting assembly on bench, remove retaining clip and
sliding fan away.
5. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Locations
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Service and Repair
Fan Blade: Service and Repair
Place fan on flat surface with leading edge facing down. If there is a clearance between fan blade
touching surface and opposite blade of more than 0.090 inch (2 mm), replace fan.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component
Locations
Coolant Temperature Sensor/Switch (For Computer): Component Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component
Locations > Page 1559
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1560
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 5 Coolant & charge temperature sensors
The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the
SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The
sensor provides a variable resistance which is proportional to coolant temperature. When the
engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and
increases engine idle speed to provide acceptable cold engine performance and allow quick warm
up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel
mixtures and lowers engine idle speed to provide proper exhaust emission control and increased
fuel economy.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations
Temperature Sensor (Gauge): Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and
Instructions
Temperature Sensor (Gauge): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and
Instructions > Page 1566
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and
Instructions > Page 1567
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 1568
Temperature Sensor (Gauge): Testing and Inspection
When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the
gauge, check for a defective sending unit or wiring as follows:
1. Ground sending unit connector leads, at the sending unit, in the vehicle.
2. With ignition in On position, a grounded input will cause the fuel or temperature gauge to read
maximum or above.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Blower Motor, Evaporator & Heater Core
Heater Core: Service and Repair Blower Motor, Evaporator & Heater Core
REMOVAL
1. Drain cooling system and discharge A/C system, if equipped. See: Heating and Air
Conditioning/Service and Repair/Refrigerant Recovery 2. Disconnect vacuum line at brake booster.
If equipped, disconnect vacuum line at water valve. 3. Disconnect heater hoses at heater core.
Plug heater core tubes to prevent spilling coolant.
Expansion Valve
4. On models with A/C, disconnect A/C plumbing at expansion valve and remove the expansion
valve from the evaporator.
Resistor Block And Drain Tube
5. Remove the condensate drain tube. 6. On all models, remove 4 nuts from unit mounting studs.
7. Remove steering column cover from left lower instrument panel. 8. Remove lower reinforcement
from below steering column. 9. Remove right side cowl and sill trim.
10. Remove bolt attaching right side instrument panel to right cowl. 11. Loosen two brackets
supporting lower edge of instrument panel to A/C and heater or heater housing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1573
Instrument Panel Assembly
12. Remove the instrument panel trim moulding from the right side dash panel. 13. Remove the
nine screws that attach the lower instrument panel to the upper instrument panel. 14. Carefully pull
the right side of lower instrument panel rearward until it reaches passenger seat. 15. Disconnect
the blower motor and resistor electrical connectors and temperature control cable. 16. Disconnect
hanger strap from evaporator heater assembly and bend rearward. 17. Pull heater-a/c assembly
rearward from dash panel and remove from vehicle. 18. Place heater-a/c assembly on workbench,
then remove vacuum harness attaching screw. Feed harness through hole in cover. 19. Remove
thirteen cover attaching screws, then the cover. Temperature control door will come out with cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1574
Fig. 15 Evaporator heater assembly
20. Remove heater core tube retaining bracket attaching screw, then lift the heater core straight up.
21. Lift evaporator up and out of unit. 22. Remove sound shield attaching screws, then blower
motor assembly.
INSTALLATION
Fig. 15 Evaporator heater assembly
1. Install the blower motor and sound shield.
2. Install the evaporator to the heater-a/c housing.
3. Install the heater core and secure with one screw through the attaching bracket.
4. Install the top cover, making sure the blend-air door is properly located in the bottom of the
heater-a/c housing. Secure top cover with 13 screws.
5. Feed the vacuum harness through the hole and secure with one screw.
6. Slide the heater-a/c unit under the lower right instrument panel. Feed the vacuum hoses through
the hole in the firewall.
7. Raise and install the heater-a/c unit to the firewall, making sure the mounting studs go
completely through and the vacuum hoses are not pinched.
8. Secure the heater-a/c unit with one screws through the hangar strap and four nuts on the
mounting studs.
9. Attach the temperature control cable, blower motor wiring, and resistor wiring.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1575
Instrument Panel Assembly
10. Position the right lower instrument panel and attach with 9 screws through the upper instrument
panel and one bolt in the right side cowl.
11. Reinstall instrument panel trim moulding.
12. Reattach all previously removed dash wiring.
13. Install steering column reinforcement, lower steering column cover and right cowl and sill trim
panels.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1576
Resistor Block And Drain Tube
14. Install the condensate drain tube.
15. Connect the vacuum hoses to the engine and water valve.
16. Connect the heater hoses and refill the engine coolent system.
Expansion Valve
17. Connect the expansion valve to the evaporator with a new gasket. Torque the torx head screws
to 100 +/- 30 in.lbs. (11 +/- 3 N-m.).
18. Connect the a/c plumbing to the expansion valve. Torque the bolt to 200 +/- 30 in.lbs. (23 +/- 3
N-m.).
19. Evacuate and recharge the a/c system.
20. Test system for overall performance.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1577
Heater Core: Service and Repair Heater Core Removal and Installation
1. Remove rear heat-a/c unit.See: Heating and Air Conditioning/Housing Assembly HVAC/Service
and Repair
2. Remove rear unit top cover.
3. Remove the heater core by carefully lifting it straight up and out of the rear unit.
4. Reverse procedure to reinstall.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Description and Operation
Temperature Gauge: Description and Operation
This system consists of a sending unit, electrical temperature gauge and an instrument voltage
regulator. As engine temperature increases or decreases, resistance of the sending unit changes,
in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the
sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature.
As engine temperature increases, resistance of the sending unit decreases, permitting an
increased current flow to the gauge, resulting in an increased temperature reading.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis
Temperature Gauge: Testing and Inspection Temperature Gauge Diagnosis
Fig. 1 Cooling System Diagnosis (Part 1 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1584
Fig. 1 Cooling System Diagnosis (Part 2 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1585
Fig. 1 Cooling System Diagnosis (Part 3 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1586
Fig. 1 Cooling System Diagnosis (Part 4 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1587
Fig. 1 Cooling System Diagnosis (Part 5 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1588
Temperature Gauge: Testing and Inspection Temperature Gauge Test
Temperature Gauge Pins
1. Remove temperature gauge assembly from the cluster. 2. Check for continuity in wire between
temperature sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check
for battery voltage across B+ pin and ground pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Locations
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Component Locations
Coolant Temperature Sensor/Switch (For Computer): Component Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Component Locations > Page 1600
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 1601
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 5 Coolant & charge temperature sensors
The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the
SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The
sensor provides a variable resistance which is proportional to coolant temperature. When the
engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and
increases engine idle speed to provide acceptable cold engine performance and allow quick warm
up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel
mixtures and lowers engine idle speed to provide proper exhaust emission control and increased
fuel economy.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations
Temperature Sensor (Gauge): Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams >
Diagram Information and Instructions
Temperature Sensor (Gauge): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams >
Diagram Information and Instructions > Page 1607
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams >
Diagram Information and Instructions > Page 1608
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page
1609
Temperature Sensor (Gauge): Testing and Inspection
When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the
gauge, check for a defective sending unit or wiring as follows:
1. Ground sending unit connector leads, at the sending unit, in the vehicle.
2. With ignition in On position, a grounded input will cause the fuel or temperature gauge to read
maximum or above.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Description and Operation
Temperature Gauge: Description and Operation
This system consists of a sending unit, electrical temperature gauge and an instrument voltage
regulator. As engine temperature increases or decreases, resistance of the sending unit changes,
in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the
sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature.
As engine temperature increases, resistance of the sending unit decreases, permitting an
increased current flow to the gauge, resulting in an increased temperature reading.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis
Temperature Gauge: Testing and Inspection Temperature Gauge Diagnosis
Fig. 1 Cooling System Diagnosis (Part 1 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1615
Fig. 1 Cooling System Diagnosis (Part 2 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1616
Fig. 1 Cooling System Diagnosis (Part 3 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1617
Fig. 1 Cooling System Diagnosis (Part 4 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1618
Fig. 1 Cooling System Diagnosis (Part 5 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1619
Temperature Gauge: Testing and Inspection Temperature Gauge Test
Temperature Gauge Pins
1. Remove temperature gauge assembly from the cluster. 2. Check for continuity in wire between
temperature sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check
for battery voltage across B+ pin and ground pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Service and Repair
Thermostat: Service and Repair
Fig. 17 Engine Thermostat
NOTE: The thermostat is located in a water box, formed in the timing belt end of the intake
manifold. This thermostat has an air bleed valve, located in the thermostat flange. It is designed to
provide the fastest warm up possible by preventing leakage through it and to guarantee a minimum
engine operating temperature of 88 to 93°C (192 to 199°F). They also automatically reach wide
open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to
around 104°C (220°F). Above this temperature the coolant temperature is controlled by the
radiator, fan, and ambient temperature, not the thermostat.
REMOVAL
1. Drain cooling system down to thermostat level or below. 2. Remove thermostat housing bolts
and housing. 3. Remove thermostat, discard gasket and clean both gasket sealing surfaces.
Fig. 18 Engine Thermostat Installed
INSTALLATION
Center thermostat in water box pocket. Check that the flange is seated correctly in the countersunk
portion of the intake manifold water box. Install new gasket on water box. Install housing over
gasket and thermostat and torque bolts to 12 Nm (133 in. lbs.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem
Water Pump: Testing and Inspection Verifying Water Pump Problem
VERIFYING WATER PUMP PROBLEM
Check for Loose Water Pump Pulley
As the pump shaft seals and bearings wear with age the pulley/shaft may develop a wobble or
lateral runout.
With the engine off and the key removed from the ignition, attempt to move the pulley from side to
side and back and forth. There should be no detectable movement. The pulley should turn
smoothly, with no rough spots.
The water pump should be replaced if any pulley wobble is detected. If the water pump is not
replaced the pump shaft may eventually seize or break.
NOTE: Incorrect belt tension (too tight) may cause premature wear of the bearings and seals.
WARNING: Never remove a radiator cap while the engine is hot. Severe personal injury may result.
Inspect for Leakage
1. With the engine "OFF" and cold:
- Check coolant level and refill if necessary.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem > Page 1627
- Inspect the water pump for leakage. Closely check the following areas: -
Inspection (weep) hole.
- Pump shaft.
- Gasket.
2. Pressurize the cooling system with a pressure tester and again check for leaks. Do not exceed
the rated pressure of the radiator cap.
NOTE: If any leaks are found, verify that they are not originating from a component near or above
the water pump (i.e. thermostat, loose radiator hoses, intake gasket, engine coolant temperature
sensor)
CAUTION: When finished, immediately re-install the radiator cap.
3. If no leaks are found, start and warm the engine until the thermostat opens. Stop the engine and
check for fresh leakage around the water pump
shaft.
NOTE: Occasionally water pumps will only leak around the shaft seals while the shaft is rotating.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem > Page 1628
Water Pump: Testing and Inspection After Repairs Operational Check
COOLING SYSTEM OPERATIONAL CHECK
IMPORTANT: Always verify the operation of the thermostat and cooling fan prior to driving the
vehicle after a cooling system repair.
HOW
- With the cooling system filled with coolant and the radiator cap installed, start the engine and
allow the coolant to warm up.
- The upper radiator hose should remain cool to the touch until the coolant within the engine block
and head has reached the thermostat opening temperature.
The thermostat opening should be indicated by a rapid warm up of the upper radiator hose.
- If upper hose gradually warms up, the thermostat may be stuck open (assuming the engine is
started cold)
- If the coolant temperature reaches the normal operating temperature (as indicated by the
temperature gauge) before the upper hose becomes warm, the engine should be turned off, and
the cooling system allowed to cool down. The thermostat may be stuck closed and should be
removed and tested.
WARNING: Never remove the radiator cap, or disconnect a coolant hose on a warm engine. A
warm cooling system may contain a large amount of stored energy in the form of steam and high
pressure, which could seriously injure you.
- If the thermostat opened properly, continue to allow the cooling system to warm up. As the
coolant temperature reaches its maximum operating temperature the electrical cooling fan should
energize. Verify the fan energizes and de-energizes.
WHY
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem > Page 1629
Thermostat Closed, Cold Engine - With the thermostat closed, coolant flow through the radiator is
blocked forcing the coolant to re-circulate through the block and head. This allows for a rapid warm
up. During this time there should be little or no coolant flow through the upper radiator hose.
Thermostat Open, Warm Engine - Once the coolant has reached normal operating temperature,
the thermostat begins to open, allowing coolant flow through the upper hose and into the radiator.
The thermostat will continue to regulate the amount of coolant flow to the radiator to maintain a
"Minimum" operating temperature.
Electric Cooling Fan Operation
The cooling fan ground circuit is controlled by the cooling fan relay. The relay opens and closes to
supply or remove ground (-) from the fan. With the ignition key "ON" positive (+) voltage is
constantly supplied to the motor.
The relay is controlled by the cooling fan temperature switch. The switch supplies the ground path
for the operating coil within the cooling fan relay.
When the coolant temperature reaches the maximum set point, the coolant switch closes and
grounds the operating coil within the fan relay. The coil then closes the relay contacts, supplying
ground to the fan motor.
When the coolant temperature fails to the lower set point, the coolant switch opens, removing
ground from the fan relay. The fan relay then opens and de-energizes the cooling fan.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Verifying Water Pump Problem > Page 1630
Water Pump: Testing and Inspection After Repairs Leak Check
AFTER REPAIRS LEAK CHECK
PURPOSE
Initially fill the cooling system and check for leaks prior to starting the engine and bleeding the
system. Although the system will not be completely full, any leaks which are detected may be fixed
before the engine and cooling system are hot.
NOTE: It is much easier to repair a leak on a cold engine than on a hot engine.
HOW
- Fill the cooling system until the radiator is full.
- Apply pressure to the system with a pressure tester.
- Carefully check for leaks around: All hoses and clamps.
- Water pump sealing surfaces.
- Any cooling system component which was removed or replaced.
- If no leaks are detected continue with the fill and bleed procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Page 1631
Water Pump: Service and Repair
Water Pump And Coolant Tube
Fig. 32 Water Pump Removal & Installation
NOTE: The water pump bolts directly to the engine block, using a gasket for pump-to-block sealing,
Fig. 32. The water pump is driven by the timing belt and is serviced as a unit.
1. Disconnect battery ground cable.
Fig. 13 Crankshaft Pulley Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Page 1632
2. Remove crankshaft drive pulleys and torsional damper, Fig. 13.
Fig. 14 Right Engine Mount & Bracket
3. Place a jack under engine to support and slightly raise engine, then remove engine mount
bracket, Fig. 14.
Fig. 15 Timing Belt Cover
4. Remove timing belt cover, Fig. 15, then mark belt running direction for reinstallation. 5. Loosen
timing belt tensioner, then remove belt and crankshaft sprocket flange shield. 6. Drain cooling
system. 7. Remove water pump mounting bolts. 8. Separate water pump from water inlet pipe Fig.
32, then remove water pump. 9. Reverse procedure to install, noting the following:
a. Use a new O-ring on water inlet pipe. b. Torque water pump mounting bolts to 27 Nm (20 ft.
lbs.). c. Refer to Engine/Timing Components/Timing Belt/Service and Repair for timing belt
installation and tensioning procedure. See:
Engine/Timing Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Page 1633
Water Pump: Tools and Equipment
RECOMMENDED TOOLS
- Drip pan - For draining coolant.
- Gasket scraper.
- Torque Wrenches: Low Range (0-50 ft-lb) for covers and brackets.
- High Range (0-150 ft-lb) for crankshaft pulley bolt.
- Full set of Metric sockets and wrenches.
Timing Belt Removal Is Required Timing light (for measuring timing before and after).
- Vacuum gauge (for measuring engine vacuum levels before and after).
Crankshaft Pulley Removal
Crankshaft Holding Tool MD998784 (used in conjunction with an old drive belt), or an air powered
impact gun (for removing the crankshaft bolt).
Timing Belt Tensioner Release
- Large flat blade screw driver (for moving timing belt tensioner).
- Fender covers.
OPTIONAL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Testing and Inspection > Page 1634
- Radiator hose removal tool.
- Cooling system pressure tester.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations
Water Pump: Fundamentals and Basics Initial Preparations
INITIAL PREPARATIONS
Disconnect Battery
When working near or around the cooling fan or drive belts, accidentally engaging the starter or
cooling fan can result in serious personal injury.
The negative battery terminal should be disconnected prior to commencing work and should not be
reconnected until after the water pump is installed and the engine is ready to restart.
Fender Covers
Fender covers will prevent damage to the vehicles finish while performing the job.
Coolant Drip Pan
Pre-position a drip pan under the vehicle to prevent any incidental spills
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1637
Water Pump: Fundamentals and Basics Removal Tips and Hints
WATER PUMP REMOVAL TIPS AND HINTS
FROZEN AND BROKEN BOLTS
Frozen and broken bolts are often a major problem when removing water pumps. Coolant can seep
into the bolt holes resulting in corrosion and frozen bolts. Prior to starting the job, spray all water
pump retaining bolts with a penetrating oil.
Upon removal, any bolt or nut which shows signs of corrosion should be replaced. The threads of
the associated bolt hole should be re-tapped or chased.
Inspect the coolant hoses, drive belts, and associated pulleys. Since these components will need to
be removed to replace the timing belt it would be convenient/time saving to have any necessary
replacement parts on hand prior to removing the pump.
COOLANT HOSES
Inspect the hoses for the following: Cracks, especially near the hose clamps.
- Swelling, look for areas of the hose that appear unnaturally bulged outwards.
NOTE: This is often caused by improper removal techniques, see Hose Removal in this article.
- Oil contamination, soft spots, oil contamination breaks down the structure of the rubber and
significantly weakens the hose.
NOTE: The oil leak should be fixed prior to replacing the hose.
- Hard or brittle hoses, as the hoses age the rubber looses its resiliency and becomes brittle. The
hoses need to be able to flex to compensate for the movement of the engine.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1638
DRIVE BELTS
Small cracks that run across that run across the ribbed surface of the belt from rib to rib , are
considered normal, These are not reasons to replace the belt.
If chunks of belt material are missing between the cracks, the belt should be replaced.
Cracks running along the rib (not across) are not normal. Any belts with cracks running along the
rib should be replaced.
Replace the belt if it has excessive wear, frayed cords or severe glazing.
Drive Pulleys
- Verify the pulleys have no side to side wobble, and rotate freely. Replace if necessary.
- Verify the pulleys are properly aligned. Adjust or replace as necessary.
Belt Removal
Do not attempt to bump the drive belts off with the starter. This practice can damage the belt,
pulley, and technician. Removing the belt by relaxing the tension will allow you to correctly adjust
the tension when installing the belt.
DRIP PAN
Prior to removing any hose or the water pump, place a large drip pan under the engine. Although
the coolant may be drained from the radiator, there is still a large amount of residual coolant
trapped in the hoses and water pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1639
HOSE REMOVAL
Prior to pulling the hose from the fitting, rotate/twist the hose on the fitting to break the grip of any
corrosion present.
If the hose is to be replaced, it may be quicker to cut hose from the fitting.
CAUTION: When cutting the hose be careful not to damage the fitting.
A radiator hose removal tool may help free up stubborn hoses.
CAUTION: Do not use any device to pry the hose off of the fitting.
- If at any time a tearing or ripping sound is heard (though the hose appears fine) the hose should
be replaced. The sound is coming from the internal reinforcing fibers embedded in the hose. Once
the fibers have been broken the hose will be subject to swelling and rupture when pressure is
applied.
WATER PUMP REMOVAL
After removing the retaining bolts the water pump may still be stuck to the engine. The original
gasket sealant may cause the pump to firmly stick to engine. A few soft blows from a rubber mallet
or block of wood will generally loosen the pump.
CAUTION: Verify that ALL of the retaining bolts are removed.
- Do not pry between the pump and the gasket. This may damage the pump sealing surface.
- Upon breaking the seal, a large amount of coolant trapped in the block will generally pour out
from the water pump opening. Be sure to have a drip pan prepositioned.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1640
Water Pump: Fundamentals and Basics Gasket Removal and Inspection
GASKET REMOVAL
- Remove all traces of the old gasket material. It only takes a very small amount of left over
material to cause the new gasket to leak.
- Never reuse gaskets. After a gasket has been initially installed and removed it will no longer be
able to compensate for the varying expansion rates of the water pump and block. An old gasket
may seal initially but as the engine heats up cools down, the old gasket will be prone to leakage.
- When removing the gasket with a gasket scraper, be very careful not to gouge the sealing
surface. Very small scratches in the sealing surface are likely to leak.
HINT: Always sharpen your gasket scraper prior to starting a job. A dull scraper is more likely to
slip and gouge the sealing surface.
- If you are using a buffing wheel to clean the gasket surface, be very careful not to burn the
surface.
CAUTION: Buffing wheels can rapidly remove metal from the sealing surface, be very careful and
check your work frequently.
INSPECTION
- Verify the gasket sealing surfaces are free of all gasket material, dirt, gouges, and contaminants
(such as coolant or oil)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1641
Water Pump: Fundamentals and Basics Installation Tips and Hints
WATER PUMP INSTALLATION TIPS AND HINTS
- Compare the old pump to the new pump and verify: Shaft lengths match exactly.
- Retaining bolt holes match exactly.
- Prior to applying the sealant to the gasket and pump, practice installing the pump to the engine. If
any problems are encountered they will be easier to solve without the silicone applied.
- Verify the retaining bolts and bolt holes have clean threads. Re-tap or chase the threads as
necessary.
- To simply the gasket installation process and minimize errors, install the gasket as follows:
1. Verify the gasket is correct. 2. Apply the sealant to the pump sealing surface and the gasket
inner surface. Apply only a light film of sealant to the sealing surfaces.
CAUTION: Excess sealant will squeeze out on the inside of the pump and may block the radiator or
heater core coolant passages.
3. Install two retaining bolts through the pump.
NOTE: This will help maintain the correct alignment of gasket in the next step.
4. While holding the bolts, place the gasket over the bolts and onto the pump sealing surface. 5.
Install the pump and gasket onto the engine.
- Do not over tighten the retaining bolts, use a torque wrench to properly tighten the bolts to the
correct specification.
CAUTION: Water pump retaining bolts may be easily broken or stripped, do not tighten the
retaining bolts with an air wrench or impact gun.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1642
- When tightening hose clamps: Position the hose squarely on the fitting.
- Verify the hose clamp is clear of the retaining rim on the fitting. Do not over tighten the clamps.
- While working on the cooling system it is a good habit to clean the radiator and A/C condenser
fins of bugs and dirt. This build up of debris can seriously reduce the cooling ability of the system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Fundamentals and Basics > Initial Preparations > Page 1643
Water Pump: Fundamentals and Basics Recommended Parts
RECOMMENDED PARTS
- New water pump, gasket and O-ring.
- RTV sealant (for sealing water pump gasket, do not apply to O-ring).
NOTE: Use only non-volatile oxygen sensor safe RTV sealant. This should be clearly indicated on
the package.
- Engine Coolant: Manual transmission - 8.9 qts. Automatic transmission- 8.8 qts
NOTE: For optimum performance, use 50/50 mixture of high quality ethylene glycol coolant and
water.
- Intake gasket set (if intake manifold removal is necessary)
NOTE: A coolant pipe runs from the back of the water pump, under the intake manifold and to the
rear of the engine. This pipe has may leak and should be inspected. Replacing the pipe requires
removing the intake manifold.
OPTIONAL, PENDING INSPECTION
- Timing belt
- Radiator hoses.
- Bypass hose.
- Drive belts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Service Precautions > Customer Safety Information
Catalytic Converter: Customer Safety Information
1. On vehicles equipped with catalytic converters the following conditions must be observed;
a. Use only "UNLEADED FUEL." b. Avoid running out of fuel. c. In case of poor engine operation
(misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Avoid push
starting the vehicle.
2. Service vehicle on regular scheduled maintenance intervals to ensure proper engine
performance and lower emission levels.
3. Always be conscious of fuel odors and excessive tailpipe emission (black smoke), these are
problem indicators.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Service Precautions > Customer Safety Information > Page 1649
Catalytic Converter: Technician Safety Information
ELECTRICAL AND ELECTRONIC
1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine.
2. Don't disconnect the battery when the engine is running.
3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all
insulators and shields are in place when reinstalling.
4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position
unless specifically directed to do so in a test procedure.
5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect
the secondary leads to disable the ignition system.
6. Do not use a self powered test lamp to check continuity.
7. Do not create any arcing to check the continuity of a circuit.
8. When charging battery, ensure battery cables are removed.
9. When replacing electronic components, disconnect the battery ground. NOTE: Before removing
battery ground, record stored trouble codes. ECM memory will be erased when ground cable is
removed.
10. When measuring voltage at the control unit harness connector, disconnect harness connector
first, then turn ignition "ON" as necessary.
11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead,
insert a pin from the harness side and perform measurements through pin.
12. Avoid getting water on any of the Fuel or Engine Control System Components.
13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension
cables.
14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper
adapters.
15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only,
never the lead itself.
16. Always use recommended power source in each testing procedure.
17. Never apply battery power to a component unless told to do so in a test procedure.
18. Do not try to disassemble the control unit.
19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start
engine.
20. In cases of electrical welding (for instance, spot welding), disconnect the climate control,
injection, cruise control, ECU and radio.
21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all
ECMs.
22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery.
FUEL SYSTEMS
1. Do not operate the fuel pump without fuel in the lines.
2. On fuel injected models do not depress the accelerator pedal while trying to start the car.
3. Handle all fuel injection related parts with care as they may easily be damaged.
4. Always use new gaskets or O-rings when installing fuel lines or injectors.
5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear
lubricant or brake fluid.
6. After servicing fuel system, check for leaks and correct as needed.
ENGINE AND EXHAUST
1. On vehicles equipped with catalytic converters, the following conditions must be observed:
a. Use only "UNLEADED FUEL". b. Avoid running out of fuel. c. In case of poor engine operation
(misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Do not
disconnect a spark plug wire with the engine running. e. Avoid push starting the vehicle. f.
If running on a dynamometer, make sure the catalytic converter is well ventilated.
g. Use caution when working near the catalytic converter to prevent the possibility of burns.
2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging
the sensor.
3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from
being fed to the injectors).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Service Precautions > Customer Safety Information > Page 1650
Catalytic Converter: Vehicle Damage Warnings
ELECTRICAL AND ELECTRONIC
1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine.
2. Don't disconnect the battery when the engine is running.
3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all
insulators and shields are in place when reinstalling.
4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position
unless specifically directed to do so in a test procedure.
5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect
the secondary leads to disable the ignition system.
6. Do not use a self powered test lamp to check continuity.
7. Do not create any arcing to check the continuity of a circuit.
8. When charging battery, ensure battery cables are removed.
9. When replacing electronic components, disconnect the battery ground. NOTE: Before removing
battery ground, record stored trouble codes. ECM memory will be erased when ground cable is
removed.
10. When measuring voltage at the control unit harness connector, disconnect harness connector
first, then turn ignition "ON" as necessary.
11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead,
insert a pin from the harness side and perform measurements through pin.
12. Avoid getting water on any of the Fuel or Engine Control System Components.
13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension
cables.
14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper
adapters.
15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only,
never the lead itself.
16. Always use recommended power source in each testing procedure.
17. Never apply battery power to a component unless told to do so in a test procedure.
18. Do not try to disassemble the control unit.
19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start
engine.
20. In cases of electrical welding (for instance, spot welding), disconnect the climate control,
injection, cruise control, ECU and radio.
21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all
ECMs.
22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery.
FUEL SYSTEMS
1. Do not operate the fuel pump without fuel in the lines.
2. On fuel injected models do not depress the accelerator pedal while trying to start the car.
3. Handle all fuel injection related parts with care as they may easily be damaged.
4. Always use new gaskets or O-rings when installing fuel lines or injectors.
5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear
lubricant or brake fluid.
6. After servicing fuel system, check for leaks and correct as needed.
ENGINE AND EXHAUST
1. On vehicles equipped with catalytic converters, the following conditions must be observed:
a. Use only "UNLEADED FUEL". b. Avoid running out of fuel. c. In case of poor engine operation
(misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Do not
disconnect a spark plug wire with the engine running. e. Avoid push starting the vehicle. f.
If running on a dynamometer, make sure the catalytic converter is well ventilated.
g. Use caution when working near the catalytic converter to prevent the possibility of burns.
2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging
the sensor.
3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from
being fed to the injectors).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Service Precautions > Page 1651
Catalytic Converter: Description and Operation
Catalytic Converter
THREE-WAY CATALYST
This catalytic converter decreases HC, CO, and NOx emissions. The catalytic converter combines
hydrocarbons (HC) and carbon monoxide (CO) with oxygen to form water (H2O) and carbon
dioxide (CO2). The three-way catalytic converter contains rhodium which reduces or separates
oxides of nitrogen (NOx) into nitrogen and oxygen. This action provides better exhaust emission
control than is obtainable by using only exhaust gas recirculation, an oxidation catalyst or engine
modifications. The three-way catalyst allows richer air/fuel mixtures, more spark advance and less
exhaust gas recirculation. All these improve both driveability and fuel economy.
Effective catalytic control of all three pollutants is possible when the correct level of CO is obtained,
and excess oxygen is reduced. Therefore, it is necessary to maintain precise control of the air/fuel
mixture entering the engine, keeping it very close to the stoichiometric point (chemically correct for
theoretical complete combustion).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Service Precautions > Page 1652
Catalytic Converter: Testing and Inspection
The exhaust system should be checked for restriction before any components are replaced. Use
the following procedures for diagnosis of the exhaust system:
Check at Oxygen Sensor
1. Carefully remove O2 sensor with proper removal tool.
2. Install Exhaust Backpressure Tester in place of 02 sensor.
3. After completing test described below, be sure to coat threads of 02 sensor with antiseize
compound prior to re-installation.
Diagnosis:
1. With the engine at normal operating temperature and running at 2500 rpm, observe the exhaust
system backpressure reading on the gauge.
2. If the backpressure exceeds 1 and 1/4 psi (8.62 kPa), a restricted exhaust system is indicated.
3. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler
failure.
4. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter
should be suspected, and replaced.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications
Exhaust Manifold: Specifications
Exhaust Manifold Nuts 191 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications > Page 1656
Exhaust Manifold: Service and Repair
EXHAUST MANIFOLD REMOVAL
1. Raise vehicle and disconnect exhaust pipe from rear cowl side.exhaust manifold at articulated
joint.
Fig. 18 Separate Articulated Joint, Disconnect Oxygen Sensor Wire
2. Disconnect Oxygen Sensor lead wire at the rear exhaust manifold.
Fig. 19 Crossover Pipe
3. Remove bolts attaching cross-over pipe to manifold. 4. Remove nuts attaching rear manifold to
cylinder head and remove manifold. 5. Lower vehicle and remove screws attaching front heat
shield to front manifold. 6. Remove bolts fastening crossover pipe to front exhaust manifold and
nuts fastening manifold to cylinder head. Remove assemblies.
INSPECTION
Fig. 20 Check Exhaust Manifold Mounting Surface
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications > Page 1657
Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with a straightedge and thickness gauge.
INSTALLATION
Fig. 21 Identify Exhaust Manifold Gaskets
NOTE: Install the gaskets with the numbers 1-3-5 embossed on the top on the rear bank and those
with numbers 2-4-6 on the front, Radiator side, bank.
1. Install rear exhaust manifold and tighten attaching nuts to 20 Nm (175 in. lbs.). 2. Attach exhaust
pipe to exhaust manifold and tighten shoulder bolt to 28 Nm (250 in. lbs.). 3. Attach crossover pipe
to exhaust manifold and tighten bolt to 69 Nm 51 ft. lbs.). 4. Connect heated oxygen sensor lead. 5.
Install front exhaust manifold and attach exhaust crossover. 6. Install front manifold heat shield and
tighten attaching screws to 15 Nm (130 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 110190A > Dec > 90 > Exhaust Flex Joint - Squeaking
Exhaust Pipe: Customer Interest Exhaust Flex Joint - Squeaking
SUBJECT: Exhaust Flex Joint Squeak - Vehicles With 2.2 Turbo, 2.5 Turbo, 3.0L EFI & 3.3L EFI
NO.: 11-01-90 Rev. A
GROUP: EXHAUST
DATE: Dec. 21, 1990
MODELS:
1989-90 (AA) Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/Convertible
(AP) Sundance/Shadow
(AS) Caravan/Grand Caravan/ Caravan C/V Voyager/Grand Voyager/Town & Country
(AY) Imperial/New Yorker Fifth Avenue
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-01-90, WHICH SHOULD
BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. "S"
VEHICLE LINE (CARAVAN/VOYAGER) HAS BEEN ADDED TO THE LABOR OPERATION
PAGES.
SYMPTOM/CONDITION
Vehicle exhibits a squeaking noise, coming from the exhaust-manifold-to-exhaust pipe coupling.
Figure 1
DIAGNOSIS
This noise is most noticeable when shifting from PARK/NEUTRAL to DRIVE or REVERSE.
>> Before performing the repair procedure on Caravan/Voyager vehicles, verify that the washers
for the muffler crossmember to frarne rail bolts (Figure
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 110190A > Dec > 90 > Exhaust Flex Joint - Squeaking
> Page 1666
1) are not contacting the crossmember. If washer-to-crossmember clearance is sufficient, and a
squeak is still present, proceed with the following repair. <<
PARTS REQUIRED
1 Exhaust Seal Ring PN 4427699
2 Bolts, Flange to Manifold PN 5217003
2 Nuts, Flange to Manifold PN 4427610
REPAIR PROCEDURE
This procedure involves replacement of the exhaust-manifold-to-exhaust-pipe sealing ring with a
revised seal ring.
1. Using Figure 3 on Page 11-2 of the 1990 Front Wheel Drive Car Service Manual (Publication #
81-270-0101) for reference, disconnect the exhaust pipe from the exhaust manifold and remove the
exhaust seal ring.
2. Install the revised seal ring, and connect the exhaust pipe to the exhaust manifold, using new
bolts and nuts as called out in PARTS REQUIRED. Tighten to 28 N-m (250 in.lbs.) torque.
NOTE: THE NEW SEAL RING WILL FIT LOOSELY ON THE PIPE. DO NOT RESIZE THE PIPE
TO FIT THE SEAL RING TIGHTLY.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
11-20-05-92 . . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 110190A > Dec > 90 > Exhaust Flex Joint Squeaking
Exhaust Pipe: All Technical Service Bulletins Exhaust Flex Joint - Squeaking
SUBJECT: Exhaust Flex Joint Squeak - Vehicles With 2.2 Turbo, 2.5 Turbo, 3.0L EFI & 3.3L EFI
NO.: 11-01-90 Rev. A
GROUP: EXHAUST
DATE: Dec. 21, 1990
MODELS:
1989-90 (AA) Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/Convertible
(AP) Sundance/Shadow
(AS) Caravan/Grand Caravan/ Caravan C/V Voyager/Grand Voyager/Town & Country
(AY) Imperial/New Yorker Fifth Avenue
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-01-90, WHICH SHOULD
BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. "S"
VEHICLE LINE (CARAVAN/VOYAGER) HAS BEEN ADDED TO THE LABOR OPERATION
PAGES.
SYMPTOM/CONDITION
Vehicle exhibits a squeaking noise, coming from the exhaust-manifold-to-exhaust pipe coupling.
Figure 1
DIAGNOSIS
This noise is most noticeable when shifting from PARK/NEUTRAL to DRIVE or REVERSE.
>> Before performing the repair procedure on Caravan/Voyager vehicles, verify that the washers
for the muffler crossmember to frarne rail bolts (Figure
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 110190A > Dec > 90 > Exhaust Flex Joint Squeaking > Page 1672
1) are not contacting the crossmember. If washer-to-crossmember clearance is sufficient, and a
squeak is still present, proceed with the following repair. <<
PARTS REQUIRED
1 Exhaust Seal Ring PN 4427699
2 Bolts, Flange to Manifold PN 5217003
2 Nuts, Flange to Manifold PN 4427610
REPAIR PROCEDURE
This procedure involves replacement of the exhaust-manifold-to-exhaust-pipe sealing ring with a
revised seal ring.
1. Using Figure 3 on Page 11-2 of the 1990 Front Wheel Drive Car Service Manual (Publication #
81-270-0101) for reference, disconnect the exhaust pipe from the exhaust manifold and remove the
exhaust seal ring.
2. Install the revised seal ring, and connect the exhaust pipe to the exhaust manifold, using new
bolts and nuts as called out in PARTS REQUIRED. Tighten to 28 N-m (250 in.lbs.) torque.
NOTE: THE NEW SEAL RING WILL FIT LOOSELY ON THE PIPE. DO NOT RESIZE THE PIPE
TO FIT THE SEAL RING TIGHTLY.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
11-20-05-92 . . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 110289 > Sep > 89 >
Exhaust System - Drone At 40-55 MPH
Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust System - Drone At 40-55 MPH
Models
1987-90 S/AS Bodies With 2.5L & 3.0L Engines
Subject
Exhaust Drone At 40-55 MPH
Index
EXHAUST
Date
September 18, 1989
No.
11-02-89
(C11-01-9)
P-3455 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH).
DIAGNOSIS
Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from
under the floor pan area in front of the first bench seat. The vibration will also be present if the
engine is run through the 2350-2450 RPM range with the transmission in neutral.
PARTS REQUIRED
1 Crossmember Assembly PN 4427322
1 Muffler Support Bracket PN 4427295
1 Heat Shield PN 4401855
4 Screw & Washer Assembly PN 6501305
4 U-Nut PN 6101283
REPAIR PROCEDURE
1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the
exhaust insulators to remain on the muffler.
2. Remove the muffler support bracket, crossmember, and heat shield.
3. Install new heat shield, using the fasteners just removed.
4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250
+/- 50 in. lbs., washer should bottom out on sleeve.
5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN
6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs.
6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the
bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs.
7. Road test vehicle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 110289 > Sep > 89 >
Exhaust System - Drone At 40-55 MPH > Page 1681
TIME ALLOWANCE: Labor Operation No.
11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 110289 > Sep
> 89 > Exhaust System - Drone At 40-55 MPH
Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Drone At 40-55
MPH
Models
1987-90 S/AS Bodies With 2.5L & 3.0L Engines
Subject
Exhaust Drone At 40-55 MPH
Index
EXHAUST
Date
September 18, 1989
No.
11-02-89
(C11-01-9)
P-3455 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH).
DIAGNOSIS
Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from
under the floor pan area in front of the first bench seat. The vibration will also be present if the
engine is run through the 2350-2450 RPM range with the transmission in neutral.
PARTS REQUIRED
1 Crossmember Assembly PN 4427322
1 Muffler Support Bracket PN 4427295
1 Heat Shield PN 4401855
4 Screw & Washer Assembly PN 6501305
4 U-Nut PN 6101283
REPAIR PROCEDURE
1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the
exhaust insulators to remain on the muffler.
2. Remove the muffler support bracket, crossmember, and heat shield.
3. Install new heat shield, using the fasteners just removed.
4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250
+/- 50 in. lbs., washer should bottom out on sleeve.
5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN
6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs.
6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the
bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs.
7. Road test vehicle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 110289 > Sep
> 89 > Exhaust System - Drone At 40-55 MPH > Page 1687
TIME ALLOWANCE: Labor Operation No.
11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 110289 > Sep > 89 > Exhaust System Drone At 40-55 MPH
Heat Shield: Customer Interest Exhaust System - Drone At 40-55 MPH
Models
1987-90 S/AS Bodies With 2.5L & 3.0L Engines
Subject
Exhaust Drone At 40-55 MPH
Index
EXHAUST
Date
September 18, 1989
No.
11-02-89
(C11-01-9)
P-3455 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH).
DIAGNOSIS
Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from
under the floor pan area in front of the first bench seat. The vibration will also be present if the
engine is run through the 2350-2450 RPM range with the transmission in neutral.
PARTS REQUIRED
1 Crossmember Assembly PN 4427322
1 Muffler Support Bracket PN 4427295
1 Heat Shield PN 4401855
4 Screw & Washer Assembly PN 6501305
4 U-Nut PN 6101283
REPAIR PROCEDURE
1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the
exhaust insulators to remain on the muffler.
2. Remove the muffler support bracket, crossmember, and heat shield.
3. Install new heat shield, using the fasteners just removed.
4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250
+/- 50 in. lbs., washer should bottom out on sleeve.
5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN
6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs.
6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the
bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs.
7. Road test vehicle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 110289 > Sep > 89 > Exhaust System Drone At 40-55 MPH > Page 1696
TIME ALLOWANCE: Labor Operation No.
11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 110289 > Sep > 89 > Exhaust
System - Drone At 40-55 MPH
Heat Shield: All Technical Service Bulletins Exhaust System - Drone At 40-55 MPH
Models
1987-90 S/AS Bodies With 2.5L & 3.0L Engines
Subject
Exhaust Drone At 40-55 MPH
Index
EXHAUST
Date
September 18, 1989
No.
11-02-89
(C11-01-9)
P-3455 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH).
DIAGNOSIS
Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from
under the floor pan area in front of the first bench seat. The vibration will also be present if the
engine is run through the 2350-2450 RPM range with the transmission in neutral.
PARTS REQUIRED
1 Crossmember Assembly PN 4427322
1 Muffler Support Bracket PN 4427295
1 Heat Shield PN 4401855
4 Screw & Washer Assembly PN 6501305
4 U-Nut PN 6101283
REPAIR PROCEDURE
1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the
exhaust insulators to remain on the muffler.
2. Remove the muffler support bracket, crossmember, and heat shield.
3. Install new heat shield, using the fasteners just removed.
4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250
+/- 50 in. lbs., washer should bottom out on sleeve.
5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN
6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs.
6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the
bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs.
7. Road test vehicle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 110289 > Sep > 89 > Exhaust
System - Drone At 40-55 MPH > Page 1702
TIME ALLOWANCE: Labor Operation No.
11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions
Body Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 1710
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
Engine Control Module: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13 > Page 1719
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds
Engine Control Module: Customer Interest ECM - Engine Die Out at Low Speeds
NO.: 18-11-91
GROUP: DRIVEABILITY
DATE: Aug. 26, 1991
SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L &
3.3L Engines
MODELS:
1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON
(AQ) CHRYSLER'S TC
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH >> ARROWS <<.
SYMPTOM/CONDITION:
Vehicle may exhibit either or both of the following conditions:
Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine
dies out when throttle is closed.
Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM
but fail to continue idling. Engine will run normally if throttle is held open.
These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on
for extended periods of time and only when the ambient temperature is above 40~ F (4~ C).
DIAGNOSIS:
Connect a DRB II tester to the vehicle diagnostic connector.
1. With the engine at normal operating temperature and with the AC on, record the AIS position
while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open
throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the
throttle open less than the AIS position at idle in DRIVE?
2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes
to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open
throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the
AIS position at idle in DRIVE?
3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following
repair procedure.
PARTS REQUIRED:
1 Single Module Engine Controller (SMEC)
1989 3.0L Engine AS Body, Federal
4639386
AS Body, California 4639001
AC Body, Federal 4639382
AC Body, California 4639384
1990 3.0L Engine
>> AS Body, Federal (except Town & Country) 4639422 <<
>> AS Body, California (except Town & Country) 4639424 <<
AC & AY Bodies, Federal 4639398
AC & AY Bodies, California 4639400
AQ Body, Federal 4650386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds >
Page 1724
AQ Body, California 4650388
>> AS Body, Federal (except Town & Country) 4639386 <<
>> AS Body, California (except Town & Country) 4639001 <<
1990 3.3L Engine AS Body, Federal
4672435
AS Body, California 4672438
AC & AY Bodies, Federal 4672440
AC & AY Bodies, California 4672431
1 Authorized Modification Label 4275086
REPAIR PROCEDURE:
This repair involves the replacement of the engine controller with a revised one.
1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS
REQUIRED.
Figure 1
2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1,
and attached near the VECI label.
* INSERT PART NUMBER USED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start
Hesitation/Tip In Sag/DTC 13
Engine Control Module: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC
13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start
Hesitation/Tip In Sag/DTC 13 > Page 1730
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low
Speeds
Engine Control Module: All Technical Service Bulletins ECM - Engine Die Out at Low Speeds
NO.: 18-11-91
GROUP: DRIVEABILITY
DATE: Aug. 26, 1991
SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L &
3.3L Engines
MODELS:
1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON
(AQ) CHRYSLER'S TC
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH >> ARROWS <<.
SYMPTOM/CONDITION:
Vehicle may exhibit either or both of the following conditions:
Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine
dies out when throttle is closed.
Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM
but fail to continue idling. Engine will run normally if throttle is held open.
These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on
for extended periods of time and only when the ambient temperature is above 40~ F (4~ C).
DIAGNOSIS:
Connect a DRB II tester to the vehicle diagnostic connector.
1. With the engine at normal operating temperature and with the AC on, record the AIS position
while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open
throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the
throttle open less than the AIS position at idle in DRIVE?
2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes
to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open
throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the
AIS position at idle in DRIVE?
3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following
repair procedure.
PARTS REQUIRED:
1 Single Module Engine Controller (SMEC)
1989 3.0L Engine AS Body, Federal
4639386
AS Body, California 4639001
AC Body, Federal 4639382
AC Body, California 4639384
1990 3.0L Engine
>> AS Body, Federal (except Town & Country) 4639422 <<
>> AS Body, California (except Town & Country) 4639424 <<
AC & AY Bodies, Federal 4639398
AC & AY Bodies, California 4639400
AQ Body, Federal 4650386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low
Speeds > Page 1735
AQ Body, California 4650388
>> AS Body, Federal (except Town & Country) 4639386 <<
>> AS Body, California (except Town & Country) 4639001 <<
1990 3.3L Engine AS Body, Federal
4672435
AS Body, California 4672438
AC & AY Bodies, Federal 4672440
AC & AY Bodies, California 4672431
1 Authorized Modification Label 4275086
REPAIR PROCEDURE:
This repair involves the replacement of the engine controller with a revised one.
1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS
REQUIRED.
Figure 1
2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1,
and attached near the VECI label.
* INSERT PART NUMBER USED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component
Locations
Engine Control Module: Component Locations
Single Module Engine Controller
The Single Module Engine Controller is located on the front left hand side of the engine
compartment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component
Locations > Page 1738
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions
Engine Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 1741
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 1742
Engine Control Module: Connector Views
14-Way Connector (1989 3.0)
Single Module Engine Controller Connector(14-Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 1743
Single Module Engine Controller Connector(60-Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 1744
60 Way (SMEC) Wiring Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1745
Engine Control Module: Description and Operation
Fig. 2 Single Module Engine Controller (SMEC)
The SMEC, Fig. 2, is mounted in the engine compartment and contains circuits necessary to
energize the ignition coil, fuel injectors and alternator field in order to minimize electrical noise in
the passenger compartment. The SMEC contains a voltage converter which converts battery
voltage into a regulated 8 volt output to energize the ignition pick up coil. The externally mounted
Automatic Shut Down (ASD) relay which interrupts power to the fuel pump, ignition coil and injector
when necessary is controlled by the SMEC. The ASD relay is turned on and off by the SMEC in
response to distributor reference pulses. When distributor reference pulses are transmitted to the
SMEC, the SMEC activates the ASD relay. However, when no reference pulse is transmitted to the
SMEC, the ASD relay is deactivated and power is shut off to the fuel control system and ignition
coil. The SMEC has been programmed to monitor several different circuits of the fuel injection
system in order to provide a self-diagnosis function. In conjunction with the self-diagnosis function,
a check engine lamp is wired into the system to indicate a failure in the monitored circuits. The
check engine lamp is illuminated for 3 seconds whenever the engine is started as a `bulb test.'
However, if the SMEC detects a malfunction in one of the monitored circuits the check engine lamp
will be illuminated and will remain on as long as the ignition key remains in the on position.
Illumination of the check engine lamp indicates that the system has entered the `limp-in' mode and
signals an immediate need for system service. If vehicle performance or the check engine lamp
indicate fuel injection system malfunctions, certain procedures should be followed. Prior to
suspecting the fuel injection service as the cause for complaints, ensure that the engine and all
related systems are in proper operating condition. After checking related systems, inspect fuel
injection components and connecting harnesses as outlined in Visual Inspection, repair system as
indicated, then road test vehicle to check system operation. If service performed during visual
inspection does not correct observed malfunctions, or if check engine lamp remains illuminated,
refer to `Obtaining fault codes' to call up fault codes stored in the SMEC memory and correct as
needed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1746
Engine Control Module: Service and Repair
1. Remove air cleaner duct from SMEC.
2. Remove battery.
3. Remove two SMEC mounting screws.
4. Remove SMEC electrical connectors.
5. Remove SMEC.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Component Locations
Main Relay (Computer/Fuel System): Component Locations
Relay Locations--next To Battery
The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the
inner fender.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Component Locations > Page 1751
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams >
Diagram Information and Instructions
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams >
Diagram Information and Instructions > Page 1754
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams >
Page 1755
Main Relay (Computer/Fuel System): Description and Operation
Relay Locations--next To Battery
The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel
pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel
injectors, and electric fuel pump at all times when the ignition switch is in the START position.
When the ignition switch is in the RUN position and the engine control module is receiving
reference signals from the distributor, power will also be supplied. If there is no reference signal
after two seconds the engine control module will de-energize the ASD and no power will be
supplied to the ignition coil, fuel injectors, or electric fuel pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > Auto Shutdown (ASD) Relay
Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay
Relay Terminal Identification
ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with
circuit codes, and color codes, and their function:
Circuit No. Terminal No. Color Code Description
J1 30 Red Has battery input voltage supplied through fusible link.
Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output
voltage to fuel pump, O2 sensor, fuel injectors, and coil.
K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine
Controller (SMEC). The SMEC provides input voltage to relay.
K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when
distributor signal is present.
N/A 87A N/A Not used in these applications.
ASD RELAY TEST
NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent.
Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no
scanner is available proceed with the following test.
1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage.
If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present
proceed to step 2.
2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to
the START position and crank the engine. If
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > Auto Shutdown (ASD) Relay > Page 1758
output voltage is present during cranking, the ASD relay is functioning normally and no further
testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3.
3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key
to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is
present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC
connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86)
wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If
continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for
SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD
relay, and test operation.
4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START
position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and
drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning,
and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If
no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14
(terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists
replace and ASD relay and test operation.
5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter
between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58
of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and
ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE
CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Polarity Protection Relay, ECM > Component Information > Locations
Polarity Protection Relay: Locations
Relay Identification
The ASD relay is found on the left inner fender apron near the left strut tower and the diagnostic
connector.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Engine Compartment Components
This vehicle utilizes the Automatic Shutdown (ASD) Relay to control the Fuel Pump operation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Component Locations
Main Relay (Computer/Fuel System): Component Locations
Relay Locations--next To Battery
The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the
inner fender.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Component Locations > Page 1770
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams >
Diagram Information and Instructions
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams >
Diagram Information and Instructions > Page 1773
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams >
Page 1774
Main Relay (Computer/Fuel System): Description and Operation
Relay Locations--next To Battery
The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel
pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel
injectors, and electric fuel pump at all times when the ignition switch is in the START position.
When the ignition switch is in the RUN position and the engine control module is receiving
reference signals from the distributor, power will also be supplied. If there is no reference signal
after two seconds the engine control module will de-energize the ASD and no power will be
supplied to the ignition coil, fuel injectors, or electric fuel pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > Auto Shutdown (ASD) Relay
Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay
Relay Terminal Identification
ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with
circuit codes, and color codes, and their function:
Circuit No. Terminal No. Color Code Description
J1 30 Red Has battery input voltage supplied through fusible link.
Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output
voltage to fuel pump, O2 sensor, fuel injectors, and coil.
K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine
Controller (SMEC). The SMEC provides input voltage to relay.
K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when
distributor signal is present.
N/A 87A N/A Not used in these applications.
ASD RELAY TEST
NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent.
Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no
scanner is available proceed with the following test.
1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage.
If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present
proceed to step 2.
2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to
the START position and crank the engine. If
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > Auto Shutdown (ASD) Relay > Page 1777
output voltage is present during cranking, the ASD relay is functioning normally and no further
testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3.
3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key
to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is
present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC
connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86)
wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If
continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for
SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD
relay, and test operation.
4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START
position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and
drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning,
and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If
no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14
(terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists
replace and ASD relay and test operation.
5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter
between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58
of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and
ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE
CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Ignition Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 1783
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
Absolute Pressure Sensor: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13 > Page 1794
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and
Fault Code 13
Absolute Pressure Sensor: Customer Interest Check Engine Lamp Comes On and Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and
Fault Code 13 > Page 1799
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and
Fault Code 13 > Page 1800
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and
Fault Code 13 > Page 1801
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set
Absolute Pressure Sensor: Customer Interest MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption
Absolute Pressure Sensor: Customer Interest Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 1810
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start
Hesitation/Tip In Sag/DTC 13
Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start
Hesitation/Tip In Sag/DTC 13 > Page 1816
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp
Comes On and Fault Code 13
Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and
Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp
Comes On and Fault Code 13 > Page 1821
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp
Comes On and Fault Code 13 > Page 1822
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp
Comes On and Fault Code 13 > Page 1823
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or
14 Set
Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption
Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption >
Page 1832
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations
Barometric Pressure Sensor: Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1840
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Component Locations
Coolant Temperature Sensor/Switch (For Computer): Component Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Component Locations > Page 1846
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 1847
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 5 Coolant & charge temperature sensors
The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the
SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The
sensor provides a variable resistance which is proportional to coolant temperature. When the
engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and
increases engine idle speed to provide acceptable cold engine performance and allow quick warm
up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel
mixtures and lowers engine idle speed to provide proper exhaust emission control and increased
fuel economy.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Senior 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1853
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
1854
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
1858
Intake Air Temperature Sensor: Description and Operation
Fig. 5 Coolant & charge temperature sensors
The charge temperature switch, Fig. 5, is mounted in the intake manifold and measures the
temperature of the air/fuel mixture. This information is used by the SMEC to modify the air/fuel
mixture.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Switch > Component Information > Locations
Intake Air Temperature Switch: Locations
RH Side Of Air Cleaner Assembly
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Component Locations
Manifold Pressure/Vacuum Sensor: Component Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Component Locations > Page 1866
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 1867
Manifold Pressure/Vacuum Sensor: Description and Operation
Fig. 3 Manifold Absolute Pressure (MAP) sensor location
The MAP sensor, Fig. 3, is mounted in the engine compartment on the dash panel and monitors
intake manifold vacuum through a line connected to the intake plenum. The sensor converts
manifold vacuum (negative pressure) and barometric pressure into electrical signals and transmits
these signals to the SMEC. The SMEC uses these signals to monitor engine load and atmospheric
conditions in order to determine the correct air/fuel mixture for vehicle operating conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 1868
Manifold Pressure/Vacuum Sensor: Service and Repair
1. Remove vacuum hose from sensor.
2. Remove sensor attaching screws, then the sensor.
3. Reverse procedure to install. Ensure proper installation of vacuum hose to sensor and sensor to
dash panel.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
On Exhaust Manifold
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Oxygen Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 1874
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1875
Oxygen Sensor: Description and Operation
Fig. 4 Oxygen sensor
The oxygen sensor, Fig. 4, produces voltage signals when exposed to oxygen in the exhaust
gasses. The oxygen content in the exhaust gasses is directly proportional to the air/fuel mixture
entering the engine, and the voltage signal produced by the sensor is inversely proportional to the
amount of oxygen remaining in the exhaust gasses. The SMEC uses these signals to determine
air/fuel mixtures entering the engine. The oxygen sensor is mounted in the rear exhaust manifold,
and the sensing element must be heated by exhaust gasses before the sensor begins to produce
voltage signals. When exhaust gas oxygen content is high (lean mixtures), the sensor produces a
low voltage. When oxygen content is low (rich mixtures), the sensor produces a higher voltage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1876
Oxygen Sensor: Service and Repair
The oxygen sensor is to be removed using tool No. C-4907 or equivalent. After removal, clean
threads in exhaust manifold using an 18mm x 1.5 x 6E tap. If reinstalling the same sensor, apply a
suitable anti-seize to threads of sensor. New sensors are packaged with an anti-seize compound
already applied to the threads and no further application is required. When installing sensor, torque
to 20 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision
Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure
Revision
Models
1989 AS
Subject
Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI
Index
MISCELLANEOUS
Date
December 29, 1989
No.
26-34-89 P-13 (C26-34-9) BODY CODE LEGEND
AS - 1989 RAM VAN, CARAVAN, VOYAGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 1881
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 1882
DIAGNOSTIC MANUAL REVISION
Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This
revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH.
1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No.
81-699-9017. Pages 136 and 137.
Please affix these revised pages in your manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 1883
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 1884
Throttle Position Sensor: Locations
LH Rear Corner Of Cylinder Head
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1887
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1888
Throttle Position Sensor: Description and Operation
The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The
sensor produces a voltage signal which increases and decreases according to throttle position. The
SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide
open throttle, acceleration and deceleration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1889
Throttle Position Sensor: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle
body mounting screws.
3. Lift TPS from throttle shaft, then remove O-ring.
4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw
to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 1898
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 1899
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 1900
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change > Page 1906
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change > Page 1907
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1912
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1913
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1914
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change > Page 1920
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change > Page 1921
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1924
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1925
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1926
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > PRNDL Switch > Page 1929
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Description and Operation > Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Description and Operation > Transmission Range Sensor > Page 1932
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > Sensor, Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > Sensor, Transmission Range > Page 1935
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > Sensor, Transmission Range > Page 1936
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > Sensor, Transmission Range > Page 1937
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
LH Side Of Engine Compartment.
Upper LH Corner Of Transaxle
Applicable to: 1989 w/Electronic Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1943
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1944
Vehicle Speed Sensor: Description and Operation
The distance sensor is located in the transaxle extension housing and signals vehicle motion to the
SMEC by generating eight pulses per axle shaft revolution. The SMEC uses this signal along with
signals from the throttle position sensor to determine between a closed throttle deceleration and a
normal idle condition, thereby allowing the SMEC to maintain desired control of the AIS motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision
Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure
Revision
Models
1989 AS
Subject
Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI
Index
MISCELLANEOUS
Date
December 29, 1989
No.
26-34-89 P-13 (C26-34-9) BODY CODE LEGEND
AS - 1989 RAM VAN, CARAVAN, VOYAGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 1950
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 1951
DIAGNOSTIC MANUAL REVISION
Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This
revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH.
1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No.
81-699-9017. Pages 136 and 137.
Please affix these revised pages in your manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 1952
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 1953
Throttle Position Sensor: Locations
LH Rear Corner Of Cylinder Head
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1956
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1957
Throttle Position Sensor: Description and Operation
The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The
sensor produces a voltage signal which increases and decreases according to throttle position. The
SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide
open throttle, acceleration and deceleration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1958
Throttle Position Sensor: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle
body mounting screws.
3. Lift TPS from throttle shaft, then remove O-ring.
4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw
to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1964
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Senior 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1970
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1971
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Locations
Ignition Switch: Locations
I/P, Cowl & Steering Column Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 1975
Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 1976
Ignition Switch: Service and Repair
Fig. 10 Ignition switch replacement
1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES.
2. Remove left lower instrument panel cover.
3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle.
4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts.
5. Lower column and disconnect ignition switch electrical connector.
6. Position ignition lock cylinder in Lock position.
7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder
assembly.
8. Remove two ignition switch attaching screws, then the switch.
9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Locations
Fuel Pressure Test Port: Locations
System not equipped with fuel pressure test port. (To test fuel pressure tee into system with
adapter.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Adjustments
Air/Fuel Mixture: Adjustments
CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw.
Never attempt to adjust idle mixture using this screw!
Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not
adjustable.
If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE
Computers and Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
IDLE SPEED
Idle speed adjustment is electronically controlled by the Automatic Idle Speed (AIS) Motor and is
not adjustable. For diagnosis of incorrect idle speed, refer to COMPUTERIZED ENGINE
CONTROLS.
IDLE SPEED
Automatic .............................................................................................................................................
.................................................................. 800 RPM Manual ..............................................................
...................................................................................................................................................... 800
RPM
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > Page 1988
Idle Speed: Testing and Inspection
1. Remove air cleaner assembly, then plug heated air door vacuum hose.
2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan
cycles ON and OFF at least once. STOP engine.
3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and
ensure basic timing is set to 12° BTDC.
4. STOP engine and reconnect coolant temperature sensor wire.
5. Disconnect PCV valve hose from intake manifold nipple.
6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV
nipple.
7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1
minute.
8. Using scanner, place read/hold switch in read position and depress ATM button until code 70
appears.
9. Place read/hold switch to hold position, then the following should occur: a.
AIS motor will fully close.
b. Idle spark advance will become fixed.
c. Idle fuel will become enriched.
d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example,
display 95 equals 95 x 10 which indicates 950 rpm.
10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is
satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE
PROCEDURES. Retest minimum air flow after throttle body cleaning.
11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install
PCV valve hose.
12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door
vacuum hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > Page 1989
Idle Speed: Adjustments
CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw.
Never attempt to adjust idle speed using this screw, unless directed to do so in a service
procedure.
Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air
Control (IAC) motor, and is not adjustable.
If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if
deposits are visible. Perform Minimum Idle Air Flow Test if applicable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
1. Loosen gas cap and allow tank pressure to release.
2. Remove wiring harness connector from any injector, then ground one injector terminal.
3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery
for approximately 10 seconds and release system pressure.
4. Remove jumper wires and service fuel system as required.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications > Cylinder Location
1988-1996 3.0L (182)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications > Cylinder Location > Page 1998
Distributor Cap From The Top - Includes Connections Inside The Cap. (Round Terminals Are Plug
Wire Connections On The Top Of The Cap.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Number One Cylinder: Locations
1988-1996 3.0L (182)
3.0L Except Stealth
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Timing Marks and Indicators > System Information > Diagrams
Timing Marks and Indicators: Diagrams
TIMING MARK 3.0L
Timing Scale Above Crank Pulley--Viewed From Front Of Car
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications
Ignition Cable: Specifications
Minimum
..................................................................................................................................................... 250
ohms per inch (3,000 ohms per foot)
Maximum
............................................................................................................................................... 1,000
ohms per inch (12,000 ohms per foot)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Component Information > Specifications
Distributor: Specifications
Distributer Adapter ...............................................................................................................................
.......................................... 14 Nm (120 in lbs) Distributer Housing Bolt .............................................
.................................................................................................................... 15 Nm (130 in lbs)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Component Information > Specifications > Page 2012
Distributor: Locations
Distributor Hold-Down
The Optical Distributor is located at the back of the engine, behind the right-hand cylinder head.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Component Information > Specifications > Page 2013
Distributor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap Specifications
Spark Plug: Specifications Gap Specifications
Refer to the Vehicle Emission Control Information (VECI) label, (under hood).
If label is gone, or not readable, verify system and use the following specification.
Plug Gap ..............................................................................................................................................
.................... 0.9 to 1.1 mm (0.039 to 0.044 in)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap Specifications > Page 2018
Spark Plug: Specifications Tightening Specifications
Spark Plug Torque ...............................................................................................................................
...................................................... 28 Nm (20 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
SERVICE SPECIFICATIONS
Compression pressure .....................................................................................................................
840 kPa (178 psi) +/- 100 kPa (14 psi) @ 250-400 rpm Maximum variation .......................................
..............................................................................................................................................................
.... 25% Manifold vacuum ....................................................................................................................
........................................................... 520 mmHg (20 in.Hg.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2022
Compression Check: Testing and Inspection
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the
throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure
gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the
compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
NOTE: Correct engine compression pressures should be 178 psi +/- 14 psi, Maximum cylinder
deviation 25%
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all
times.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 2026
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters. No provision for adjustment is provided.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr >
94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13
Absolute Pressure Sensor: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr >
94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2036
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep >
91 > Check Engine Lamp Comes On and Fault Code 13
Absolute Pressure Sensor: Customer Interest Check Engine Lamp Comes On and Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep >
91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2041
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep >
91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2042
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep >
91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2043
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180390 > Jan >
90 > MAP Sensor - DTC's 13 or 14 Set
Absolute Pressure Sensor: Customer Interest MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct >
89 > Engine - Oil Consumption
Absolute Pressure Sensor: Customer Interest Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct >
89 > Engine - Oil Consumption > Page 2052
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13
Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2058
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13
Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and
Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2063
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2064
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2065
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set
Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
091689 > Oct > 89 > Engine - Oil Consumption
Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: >
091689 > Oct > 89 > Engine - Oil Consumption > Page 2074
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor
> Component Information > Locations
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor
> Component Information > Locations > Page 2078
Intake Air Temperature Sensor: Description and Operation
Fig. 5 Coolant & charge temperature sensors
The charge temperature switch, Fig. 5, is mounted in the intake manifold and measures the
temperature of the air/fuel mixture. This information is used by the SMEC to modify the air/fuel
mixture.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Switch >
Component Information > Locations
Intake Air Temperature Switch: Locations
RH Side Of Air Cleaner Assembly
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed)
> Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 182188 >
Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients
Auxiliary Air Valve (Idle Speed): Customer Interest AIS Motor - Erratic Idle Speed In Cold Ambients
Models
1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines
Subject
Erratic Idle Speed in Cold Ambients
Index
DRIVEABILITY
Date
December 12, 1988
No.
18-21-88
(C18-26) SYMPTOM/CONDITION
Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor
failure. A revised A.I.S. motor is now available for those areas.
NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC
TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES.
PARTS REQUIRED
1987-1988 3.0L VEHICLES
1 A.I.S. Motor PN 4458366
1989 3.0L VEHICLES
1 A.I.S. Motor PN 4458355
REPAIR PROCEDURE
This repair involves replacing the A.I.S. motor with a revised A.I.S. motor.
1. Remove A.I.S. motor as outlined in the service manual.
NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO
TECHNICAL SERVICE BULLETIN 14-07-88.
2. Install new A.I.S. motor as outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.
14-30-23-93 . . . . . . . . . 0.5 Hrs.
FAILURE CODE: 61 - Intermittent Operation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed):
> 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients
Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins AIS Motor - Erratic Idle Speed In
Cold Ambients
Models
1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines
Subject
Erratic Idle Speed in Cold Ambients
Index
DRIVEABILITY
Date
December 12, 1988
No.
18-21-88
(C18-26) SYMPTOM/CONDITION
Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor
failure. A revised A.I.S. motor is now available for those areas.
NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC
TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES.
PARTS REQUIRED
1987-1988 3.0L VEHICLES
1 A.I.S. Motor PN 4458366
1989 3.0L VEHICLES
1 A.I.S. Motor PN 4458355
REPAIR PROCEDURE
This repair involves replacing the A.I.S. motor with a revised A.I.S. motor.
1. Remove A.I.S. motor as outlined in the service manual.
NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO
TECHNICAL SERVICE BULLETIN 14-07-88.
2. Install new A.I.S. motor as outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.
14-30-23-93 . . . . . . . . . 0.5 Hrs.
FAILURE CODE: 61 - Intermittent Operation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Component Information > Locations
Barometric Pressure Sensor: Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Body Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2102
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2107
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Component Locations
Coolant Temperature Sensor/Switch (For Computer): Component Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 2113
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2114
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 5 Coolant & charge temperature sensors
The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the
SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The
sensor provides a variable resistance which is proportional to coolant temperature. When the
engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and
increases engine idle speed to provide acceptable cold engine performance and allow quick warm
up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel
mixtures and lowers engine idle speed to provide proper exhaust emission control and increased
fuel economy.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Senior 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2120
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Page 2121
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
Data Link Connector: Locations
Engine Compartment Components
The Diagnostic Connector is found on the left side of the engine compartment, behind the battery,
and near the left strut tower. It is also near the Auto Shut Down (ASD) Relay.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94
> PCM - Cold Start Hesitation/Tip In Sag/DTC 13
Engine Control Module: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94
> PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2133
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91
> ECM - Engine Die Out at Low Speeds
Engine Control Module: Customer Interest ECM - Engine Die Out at Low Speeds
NO.: 18-11-91
GROUP: DRIVEABILITY
DATE: Aug. 26, 1991
SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L &
3.3L Engines
MODELS:
1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON
(AQ) CHRYSLER'S TC
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH >> ARROWS <<.
SYMPTOM/CONDITION:
Vehicle may exhibit either or both of the following conditions:
Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine
dies out when throttle is closed.
Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM
but fail to continue idling. Engine will run normally if throttle is held open.
These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on
for extended periods of time and only when the ambient temperature is above 40~ F (4~ C).
DIAGNOSIS:
Connect a DRB II tester to the vehicle diagnostic connector.
1. With the engine at normal operating temperature and with the AC on, record the AIS position
while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open
throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the
throttle open less than the AIS position at idle in DRIVE?
2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes
to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open
throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the
AIS position at idle in DRIVE?
3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following
repair procedure.
PARTS REQUIRED:
1 Single Module Engine Controller (SMEC)
1989 3.0L Engine AS Body, Federal
4639386
AS Body, California 4639001
AC Body, Federal 4639382
AC Body, California 4639384
1990 3.0L Engine
>> AS Body, Federal (except Town & Country) 4639422 <<
>> AS Body, California (except Town & Country) 4639424 <<
AC & AY Bodies, Federal 4639398
AC & AY Bodies, California 4639400
AQ Body, Federal 4650386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91
> ECM - Engine Die Out at Low Speeds > Page 2138
AQ Body, California 4650388
>> AS Body, Federal (except Town & Country) 4639386 <<
>> AS Body, California (except Town & Country) 4639001 <<
1990 3.3L Engine AS Body, Federal
4672435
AS Body, California 4672438
AC & AY Bodies, Federal 4672440
AC & AY Bodies, California 4672431
1 Authorized Modification Label 4275086
REPAIR PROCEDURE:
This repair involves the replacement of the engine controller with a revised one.
1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS
REQUIRED.
Figure 1
2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1,
and attached near the VECI label.
* INSERT PART NUMBER USED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694
> Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13
Engine Control Module: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC
13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694
> Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2144
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191
> Aug > 91 > ECM - Engine Die Out at Low Speeds
Engine Control Module: All Technical Service Bulletins ECM - Engine Die Out at Low Speeds
NO.: 18-11-91
GROUP: DRIVEABILITY
DATE: Aug. 26, 1991
SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L &
3.3L Engines
MODELS:
1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON
(AQ) CHRYSLER'S TC
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH >> ARROWS <<.
SYMPTOM/CONDITION:
Vehicle may exhibit either or both of the following conditions:
Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine
dies out when throttle is closed.
Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM
but fail to continue idling. Engine will run normally if throttle is held open.
These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on
for extended periods of time and only when the ambient temperature is above 40~ F (4~ C).
DIAGNOSIS:
Connect a DRB II tester to the vehicle diagnostic connector.
1. With the engine at normal operating temperature and with the AC on, record the AIS position
while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open
throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the
throttle open less than the AIS position at idle in DRIVE?
2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes
to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open
throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the
AIS position at idle in DRIVE?
3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following
repair procedure.
PARTS REQUIRED:
1 Single Module Engine Controller (SMEC)
1989 3.0L Engine AS Body, Federal
4639386
AS Body, California 4639001
AC Body, Federal 4639382
AC Body, California 4639384
1990 3.0L Engine
>> AS Body, Federal (except Town & Country) 4639422 <<
>> AS Body, California (except Town & Country) 4639424 <<
AC & AY Bodies, Federal 4639398
AC & AY Bodies, California 4639400
AQ Body, Federal 4650386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191
> Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 2149
AQ Body, California 4650388
>> AS Body, Federal (except Town & Country) 4639386 <<
>> AS Body, California (except Town & Country) 4639001 <<
1990 3.3L Engine AS Body, Federal
4672435
AS Body, California 4672438
AC & AY Bodies, Federal 4672440
AC & AY Bodies, California 4672431
1 Authorized Modification Label 4275086
REPAIR PROCEDURE:
This repair involves the replacement of the engine controller with a revised one.
1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS
REQUIRED.
Figure 1
2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1,
and attached near the VECI label.
* INSERT PART NUMBER USED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Component Locations
Engine Control Module: Component Locations
Single Module Engine Controller
The Single Module Engine Controller is located on the front left hand side of the engine
compartment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Component Locations > Page 2152
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Engine Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2155
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2156
Engine Control Module: Connector Views
14-Way Connector (1989 3.0)
Single Module Engine Controller Connector(14-Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2157
Single Module Engine Controller Connector(60-Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2158
60 Way (SMEC) Wiring Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Page 2159
Engine Control Module: Description and Operation
Fig. 2 Single Module Engine Controller (SMEC)
The SMEC, Fig. 2, is mounted in the engine compartment and contains circuits necessary to
energize the ignition coil, fuel injectors and alternator field in order to minimize electrical noise in
the passenger compartment. The SMEC contains a voltage converter which converts battery
voltage into a regulated 8 volt output to energize the ignition pick up coil. The externally mounted
Automatic Shut Down (ASD) relay which interrupts power to the fuel pump, ignition coil and injector
when necessary is controlled by the SMEC. The ASD relay is turned on and off by the SMEC in
response to distributor reference pulses. When distributor reference pulses are transmitted to the
SMEC, the SMEC activates the ASD relay. However, when no reference pulse is transmitted to the
SMEC, the ASD relay is deactivated and power is shut off to the fuel control system and ignition
coil. The SMEC has been programmed to monitor several different circuits of the fuel injection
system in order to provide a self-diagnosis function. In conjunction with the self-diagnosis function,
a check engine lamp is wired into the system to indicate a failure in the monitored circuits. The
check engine lamp is illuminated for 3 seconds whenever the engine is started as a `bulb test.'
However, if the SMEC detects a malfunction in one of the monitored circuits the check engine lamp
will be illuminated and will remain on as long as the ignition key remains in the on position.
Illumination of the check engine lamp indicates that the system has entered the `limp-in' mode and
signals an immediate need for system service. If vehicle performance or the check engine lamp
indicate fuel injection system malfunctions, certain procedures should be followed. Prior to
suspecting the fuel injection service as the cause for complaints, ensure that the engine and all
related systems are in proper operating condition. After checking related systems, inspect fuel
injection components and connecting harnesses as outlined in Visual Inspection, repair system as
indicated, then road test vehicle to check system operation. If service performed during visual
inspection does not correct observed malfunctions, or if check engine lamp remains illuminated,
refer to `Obtaining fault codes' to call up fault codes stored in the SMEC memory and correct as
needed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Page 2160
Engine Control Module: Service and Repair
1. Remove air cleaner duct from SMEC.
2. Remove battery.
3. Remove two SMEC mounting screws.
4. Remove SMEC electrical connectors.
5. Remove SMEC.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations
Idle Speed/Throttle Actuator - Electronic: Component Locations
LH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 2165
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2166
Idle Speed/Throttle Actuator - Electronic: Description and Operation
The AIS motor is operated by the SMEC and controls engine idle speed by controlling air flow
through the throttle body by-pass channel. The SMEC computes proper idle speed based in signals
from vehicle and engine sensors and the switch inputs, and transmits voltage signals to the AIS
motor to open or close the by-pass channel in order to maintain the proper engine speed. Basic,
no-load idle speed is determined by the amount of air flowing through the throttle body past the
closed throttle plate. The AIS motor alters idle speed by allowing increased air flow through the
by-pass channel; increasing idle speed when the channel is opened and decreasing idle speed
when the channel is closed. In addition, the AIS motor is signaled to open the by-pass channel
during deceleration to prevent stalling and mixture enrichment caused by sudden closing of the
throttle plate.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2167
Idle Speed/Throttle Actuator - Electronic: Service and Repair
1. Disconnect battery ground cable, then remove air cleaner assembly.
2. Disconnect four pin connector from AIS, then remove temperature sending unit from throttle
body housing.
3. Remove two AIS to throttle body torx head retaining screws.
4. Remove AIS from throttle body housing with O-ring.
5. Reverse procedure to install. Install new O-ring and torque retaining screws to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Component Locations
Main Relay (Computer/Fuel System): Component Locations
Relay Locations--next To Battery
The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the
inner fender.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Component Locations > Page 2172
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Diagrams > Diagram Information and Instructions
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Diagrams > Diagram Information and Instructions > Page 2175
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Diagrams > Page 2176
Main Relay (Computer/Fuel System): Description and Operation
Relay Locations--next To Battery
The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel
pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel
injectors, and electric fuel pump at all times when the ignition switch is in the START position.
When the ignition switch is in the RUN position and the engine control module is receiving
reference signals from the distributor, power will also be supplied. If there is no reference signal
after two seconds the engine control module will de-energize the ASD and no power will be
supplied to the ignition coil, fuel injectors, or electric fuel pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay
Relay Terminal Identification
ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with
circuit codes, and color codes, and their function:
Circuit No. Terminal No. Color Code Description
J1 30 Red Has battery input voltage supplied through fusible link.
Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output
voltage to fuel pump, O2 sensor, fuel injectors, and coil.
K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine
Controller (SMEC). The SMEC provides input voltage to relay.
K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when
distributor signal is present.
N/A 87A N/A Not used in these applications.
ASD RELAY TEST
NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent.
Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no
scanner is available proceed with the following test.
1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage.
If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present
proceed to step 2.
2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to
the START position and crank the engine. If
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2179
output voltage is present during cranking, the ASD relay is functioning normally and no further
testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3.
3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key
to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is
present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC
connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86)
wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If
continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for
SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD
relay, and test operation.
4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START
position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and
drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning,
and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If
no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14
(terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists
replace and ASD relay and test operation.
5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter
between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58
of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and
ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE
CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Malfunction Indicator Lamp Driver Module > Component Information > Locations
Malfunction Indicator Lamp Driver Module: Locations
Upper I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Component Locations
Manifold Pressure/Vacuum Sensor: Component Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Component Locations > Page 2188
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 2189
Manifold Pressure/Vacuum Sensor: Description and Operation
Fig. 3 Manifold Absolute Pressure (MAP) sensor location
The MAP sensor, Fig. 3, is mounted in the engine compartment on the dash panel and monitors
intake manifold vacuum through a line connected to the intake plenum. The sensor converts
manifold vacuum (negative pressure) and barometric pressure into electrical signals and transmits
these signals to the SMEC. The SMEC uses these signals to monitor engine load and atmospheric
conditions in order to determine the correct air/fuel mixture for vehicle operating conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 2190
Manifold Pressure/Vacuum Sensor: Service and Repair
1. Remove vacuum hose from sensor.
2. Remove sensor attaching screws, then the sensor.
3. Reverse procedure to install. Ensure proper installation of vacuum hose to sensor and sensor to
dash panel.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations
Oxygen Sensor: Locations
On Exhaust Manifold
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Oxygen Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 2196
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 2197
Oxygen Sensor: Description and Operation
Fig. 4 Oxygen sensor
The oxygen sensor, Fig. 4, produces voltage signals when exposed to oxygen in the exhaust
gasses. The oxygen content in the exhaust gasses is directly proportional to the air/fuel mixture
entering the engine, and the voltage signal produced by the sensor is inversely proportional to the
amount of oxygen remaining in the exhaust gasses. The SMEC uses these signals to determine
air/fuel mixtures entering the engine. The oxygen sensor is mounted in the rear exhaust manifold,
and the sensing element must be heated by exhaust gasses before the sensor begins to produce
voltage signals. When exhaust gas oxygen content is high (lean mixtures), the sensor produces a
low voltage. When oxygen content is low (rich mixtures), the sensor produces a higher voltage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 2198
Oxygen Sensor: Service and Repair
The oxygen sensor is to be removed using tool No. C-4907 or equivalent. After removal, clean
threads in exhaust manifold using an 18mm x 1.5 x 6E tap. If reinstalling the same sensor, apply a
suitable anti-seize to threads of sensor. New sensors are packaged with an anti-seize compound
already applied to the threads and no further application is required. When installing sensor, torque
to 20 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Body Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 2204
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13
Engine Control Module: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 >
Page 2213
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds
Engine Control Module: Customer Interest ECM - Engine Die Out at Low Speeds
NO.: 18-11-91
GROUP: DRIVEABILITY
DATE: Aug. 26, 1991
SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L &
3.3L Engines
MODELS:
1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON
(AQ) CHRYSLER'S TC
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH >> ARROWS <<.
SYMPTOM/CONDITION:
Vehicle may exhibit either or both of the following conditions:
Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine
dies out when throttle is closed.
Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM
but fail to continue idling. Engine will run normally if throttle is held open.
These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on
for extended periods of time and only when the ambient temperature is above 40~ F (4~ C).
DIAGNOSIS:
Connect a DRB II tester to the vehicle diagnostic connector.
1. With the engine at normal operating temperature and with the AC on, record the AIS position
while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open
throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the
throttle open less than the AIS position at idle in DRIVE?
2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes
to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open
throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the
AIS position at idle in DRIVE?
3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following
repair procedure.
PARTS REQUIRED:
1 Single Module Engine Controller (SMEC)
1989 3.0L Engine AS Body, Federal
4639386
AS Body, California 4639001
AC Body, Federal 4639382
AC Body, California 4639384
1990 3.0L Engine
>> AS Body, Federal (except Town & Country) 4639422 <<
>> AS Body, California (except Town & Country) 4639424 <<
AC & AY Bodies, Federal 4639398
AC & AY Bodies, California 4639400
AQ Body, Federal 4650386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 2218
AQ Body, California 4650388
>> AS Body, Federal (except Town & Country) 4639386 <<
>> AS Body, California (except Town & Country) 4639001 <<
1990 3.3L Engine AS Body, Federal
4672435
AS Body, California 4672438
AC & AY Bodies, Federal 4672440
AC & AY Bodies, California 4672431
1 Authorized Modification Label 4275086
REPAIR PROCEDURE:
This repair involves the replacement of the engine controller with a revised one.
1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS
REQUIRED.
Figure 1
2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1,
and attached near the VECI label.
* INSERT PART NUMBER USED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC
13
Engine Control Module: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC
13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC
13 > Page 2224
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds
Engine Control Module: All Technical Service Bulletins ECM - Engine Die Out at Low Speeds
NO.: 18-11-91
GROUP: DRIVEABILITY
DATE: Aug. 26, 1991
SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L &
3.3L Engines
MODELS:
1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON
(AQ) CHRYSLER'S TC
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH >> ARROWS <<.
SYMPTOM/CONDITION:
Vehicle may exhibit either or both of the following conditions:
Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine
dies out when throttle is closed.
Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM
but fail to continue idling. Engine will run normally if throttle is held open.
These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on
for extended periods of time and only when the ambient temperature is above 40~ F (4~ C).
DIAGNOSIS:
Connect a DRB II tester to the vehicle diagnostic connector.
1. With the engine at normal operating temperature and with the AC on, record the AIS position
while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open
throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the
throttle open less than the AIS position at idle in DRIVE?
2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes
to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open
throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the
AIS position at idle in DRIVE?
3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following
repair procedure.
PARTS REQUIRED:
1 Single Module Engine Controller (SMEC)
1989 3.0L Engine AS Body, Federal
4639386
AS Body, California 4639001
AC Body, Federal 4639382
AC Body, California 4639384
1990 3.0L Engine
>> AS Body, Federal (except Town & Country) 4639422 <<
>> AS Body, California (except Town & Country) 4639424 <<
AC & AY Bodies, Federal 4639398
AC & AY Bodies, California 4639400
AQ Body, Federal 4650386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds >
Page 2229
AQ Body, California 4650388
>> AS Body, Federal (except Town & Country) 4639386 <<
>> AS Body, California (except Town & Country) 4639001 <<
1990 3.3L Engine AS Body, Federal
4672435
AS Body, California 4672438
AC & AY Bodies, Federal 4672440
AC & AY Bodies, California 4672431
1 Authorized Modification Label 4275086
REPAIR PROCEDURE:
This repair involves the replacement of the engine controller with a revised one.
1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS
REQUIRED.
Figure 1
2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1,
and attached near the VECI label.
* INSERT PART NUMBER USED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations
Engine Control Module: Component Locations
Single Module Engine Controller
The Single Module Engine Controller is located on the front left hand side of the engine
compartment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations >
Page 2232
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions
Engine Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 2235
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 2236
Engine Control Module: Connector Views
14-Way Connector (1989 3.0)
Single Module Engine Controller Connector(14-Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 2237
Single Module Engine Controller Connector(60-Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 2238
60 Way (SMEC) Wiring Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2239
Engine Control Module: Description and Operation
Fig. 2 Single Module Engine Controller (SMEC)
The SMEC, Fig. 2, is mounted in the engine compartment and contains circuits necessary to
energize the ignition coil, fuel injectors and alternator field in order to minimize electrical noise in
the passenger compartment. The SMEC contains a voltage converter which converts battery
voltage into a regulated 8 volt output to energize the ignition pick up coil. The externally mounted
Automatic Shut Down (ASD) relay which interrupts power to the fuel pump, ignition coil and injector
when necessary is controlled by the SMEC. The ASD relay is turned on and off by the SMEC in
response to distributor reference pulses. When distributor reference pulses are transmitted to the
SMEC, the SMEC activates the ASD relay. However, when no reference pulse is transmitted to the
SMEC, the ASD relay is deactivated and power is shut off to the fuel control system and ignition
coil. The SMEC has been programmed to monitor several different circuits of the fuel injection
system in order to provide a self-diagnosis function. In conjunction with the self-diagnosis function,
a check engine lamp is wired into the system to indicate a failure in the monitored circuits. The
check engine lamp is illuminated for 3 seconds whenever the engine is started as a `bulb test.'
However, if the SMEC detects a malfunction in one of the monitored circuits the check engine lamp
will be illuminated and will remain on as long as the ignition key remains in the on position.
Illumination of the check engine lamp indicates that the system has entered the `limp-in' mode and
signals an immediate need for system service. If vehicle performance or the check engine lamp
indicate fuel injection system malfunctions, certain procedures should be followed. Prior to
suspecting the fuel injection service as the cause for complaints, ensure that the engine and all
related systems are in proper operating condition. After checking related systems, inspect fuel
injection components and connecting harnesses as outlined in Visual Inspection, repair system as
indicated, then road test vehicle to check system operation. If service performed during visual
inspection does not correct observed malfunctions, or if check engine lamp remains illuminated,
refer to `Obtaining fault codes' to call up fault codes stored in the SMEC memory and correct as
needed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2240
Engine Control Module: Service and Repair
1. Remove air cleaner duct from SMEC.
2. Remove battery.
3. Remove two SMEC mounting screws.
4. Remove SMEC electrical connectors.
5. Remove SMEC.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Component Locations
Main Relay (Computer/Fuel System): Component Locations
Relay Locations--next To Battery
The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the
inner fender.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Component Locations > Page 2245
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram
Information and Instructions
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram
Information and Instructions > Page 2248
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 2249
Main Relay (Computer/Fuel System): Description and Operation
Relay Locations--next To Battery
The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel
pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel
injectors, and electric fuel pump at all times when the ignition switch is in the START position.
When the ignition switch is in the RUN position and the engine control module is receiving
reference signals from the distributor, power will also be supplied. If there is no reference signal
after two seconds the engine control module will de-energize the ASD and no power will be
supplied to the ignition coil, fuel injectors, or electric fuel pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection
> Auto Shutdown (ASD) Relay
Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay
Relay Terminal Identification
ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with
circuit codes, and color codes, and their function:
Circuit No. Terminal No. Color Code Description
J1 30 Red Has battery input voltage supplied through fusible link.
Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output
voltage to fuel pump, O2 sensor, fuel injectors, and coil.
K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine
Controller (SMEC). The SMEC provides input voltage to relay.
K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when
distributor signal is present.
N/A 87A N/A Not used in these applications.
ASD RELAY TEST
NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent.
Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no
scanner is available proceed with the following test.
1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage.
If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present
proceed to step 2.
2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to
the START position and crank the engine. If
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection
> Auto Shutdown (ASD) Relay > Page 2252
output voltage is present during cranking, the ASD relay is functioning normally and no further
testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3.
3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key
to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is
present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC
connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86)
wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If
continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for
SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD
relay, and test operation.
4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START
position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and
drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning,
and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If
no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14
(terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists
replace and ASD relay and test operation.
5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter
between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58
of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and
ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE
CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Polarity Protection Relay, ECM > Component Information > Locations
Polarity Protection Relay: Locations
Relay Identification
The ASD relay is found on the left inner fender apron near the left strut tower and the diagnostic
connector.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Polarity Protection Relay, ECM
> Component Information > Locations
Polarity Protection Relay: Locations
Relay Identification
The ASD relay is found on the left inner fender apron near the left strut tower and the diagnostic
connector.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13
Absolute Pressure Sensor: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 >
Page 2268
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code
13
Absolute Pressure Sensor: Customer Interest Check Engine Lamp Comes On and Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code
13 > Page 2273
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code
13 > Page 2274
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code
13 > Page 2275
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set
Absolute Pressure Sensor: Customer Interest MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption
Absolute Pressure Sensor: Customer Interest Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2284
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In
Sag/DTC 13 > Page 2290
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13
Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and
Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 2295
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 2296
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault
Code 13 > Page 2297
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set
Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption
Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2306
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations
Barometric Pressure Sensor: Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 2314
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Component Locations
Coolant Temperature Sensor/Switch (For Computer): Component Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Component Locations > Page 2320
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 2321
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 5 Coolant & charge temperature sensors
The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the
SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The
sensor provides a variable resistance which is proportional to coolant temperature. When the
engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and
increases engine idle speed to provide acceptable cold engine performance and allow quick warm
up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel
mixtures and lowers engine idle speed to provide proper exhaust emission control and increased
fuel economy.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Senior 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2327
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2328
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2332
Intake Air Temperature Sensor: Description and Operation
Fig. 5 Coolant & charge temperature sensors
The charge temperature switch, Fig. 5, is mounted in the intake manifold and measures the
temperature of the air/fuel mixture. This information is used by the SMEC to modify the air/fuel
mixture.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Switch > Component Information > Locations
Intake Air Temperature Switch: Locations
RH Side Of Air Cleaner Assembly
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component
Locations
Manifold Pressure/Vacuum Sensor: Component Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component
Locations > Page 2340
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2341
Manifold Pressure/Vacuum Sensor: Description and Operation
Fig. 3 Manifold Absolute Pressure (MAP) sensor location
The MAP sensor, Fig. 3, is mounted in the engine compartment on the dash panel and monitors
intake manifold vacuum through a line connected to the intake plenum. The sensor converts
manifold vacuum (negative pressure) and barometric pressure into electrical signals and transmits
these signals to the SMEC. The SMEC uses these signals to monitor engine load and atmospheric
conditions in order to determine the correct air/fuel mixture for vehicle operating conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2342
Manifold Pressure/Vacuum Sensor: Service and Repair
1. Remove vacuum hose from sensor.
2. Remove sensor attaching screws, then the sensor.
3. Reverse procedure to install. Ensure proper installation of vacuum hose to sensor and sensor to
dash panel.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
On Exhaust Manifold
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Oxygen Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2348
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2349
Oxygen Sensor: Description and Operation
Fig. 4 Oxygen sensor
The oxygen sensor, Fig. 4, produces voltage signals when exposed to oxygen in the exhaust
gasses. The oxygen content in the exhaust gasses is directly proportional to the air/fuel mixture
entering the engine, and the voltage signal produced by the sensor is inversely proportional to the
amount of oxygen remaining in the exhaust gasses. The SMEC uses these signals to determine
air/fuel mixtures entering the engine. The oxygen sensor is mounted in the rear exhaust manifold,
and the sensing element must be heated by exhaust gasses before the sensor begins to produce
voltage signals. When exhaust gas oxygen content is high (lean mixtures), the sensor produces a
low voltage. When oxygen content is low (rich mixtures), the sensor produces a higher voltage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2350
Oxygen Sensor: Service and Repair
The oxygen sensor is to be removed using tool No. C-4907 or equivalent. After removal, clean
threads in exhaust manifold using an 18mm x 1.5 x 6E tap. If reinstalling the same sensor, apply a
suitable anti-seize to threads of sensor. New sensors are packaged with an anti-seize compound
already applied to the threads and no further application is required. When installing sensor, torque
to 20 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel
Injection - TPS Diagnostic Procedure Revision
Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure
Revision
Models
1989 AS
Subject
Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI
Index
MISCELLANEOUS
Date
December 29, 1989
No.
26-34-89 P-13 (C26-34-9) BODY CODE LEGEND
AS - 1989 RAM VAN, CARAVAN, VOYAGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel
Injection - TPS Diagnostic Procedure Revision > Page 2355
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel
Injection - TPS Diagnostic Procedure Revision > Page 2356
DIAGNOSTIC MANUAL REVISION
Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This
revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH.
1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No.
81-699-9017. Pages 136 and 137.
Please affix these revised pages in your manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page
2357
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page
2358
Throttle Position Sensor: Locations
LH Rear Corner Of Cylinder Head
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 2361
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2362
Throttle Position Sensor: Description and Operation
The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The
sensor produces a voltage signal which increases and decreases according to throttle position. The
SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide
open throttle, acceleration and deceleration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2363
Throttle Position Sensor: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle
body mounting screws.
3. Lift TPS from throttle shaft, then remove O-ring.
4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw
to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2372
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2373
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2374
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change > Page 2380
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change > Page 2381
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 2386
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 2387
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 2388
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change > Page 2394
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change > Page 2395
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Transmission Solenoid and Pressure Switch Assembly > Page 2398
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Transmission Solenoid and Pressure Switch Assembly > Page 2399
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Transmission Solenoid and Pressure Switch Assembly > Page 2400
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
PRNDL Switch > Page 2403
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and
Operation > Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and
Operation > Transmission Range Sensor > Page 2406
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and
Repair > Sensor, Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and
Repair > Sensor, Transmission Range > Page 2409
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and
Repair > Sensor, Transmission Range > Page 2410
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and
Repair > Sensor, Transmission Range > Page 2411
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
LH Side Of Engine Compartment.
Upper LH Corner Of Transaxle
Applicable to: 1989 w/Electronic Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2417
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2418
Vehicle Speed Sensor: Description and Operation
The distance sensor is located in the transaxle extension housing and signals vehicle motion to the
SMEC by generating eight pulses per axle shaft revolution. The SMEC uses this signal along with
signals from the throttle position sensor to determine between a closed throttle deceleration and a
normal idle condition, thereby allowing the SMEC to maintain desired control of the AIS motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision
Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure
Revision
Models
1989 AS
Subject
Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI
Index
MISCELLANEOUS
Date
December 29, 1989
No.
26-34-89 P-13 (C26-34-9) BODY CODE LEGEND
AS - 1989 RAM VAN, CARAVAN, VOYAGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2423
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2424
DIAGNOSTIC MANUAL REVISION
Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This
revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH.
1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No.
81-699-9017. Pages 136 and 137.
Please affix these revised pages in your manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 2425
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 2426
Throttle Position Sensor: Locations
LH Rear Corner Of Cylinder Head
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2429
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Page 2430
Throttle Position Sensor: Description and Operation
The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The
sensor produces a voltage signal which increases and decreases according to throttle position. The
SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide
open throttle, acceleration and deceleration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Page 2431
Throttle Position Sensor: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle
body mounting screws.
3. Lift TPS from throttle shaft, then remove O-ring.
4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw
to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2440
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2441
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2442
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page
2448
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page
2449
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
2454
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
2455
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
2456
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2462
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2463
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
2466
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
2467
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
2468
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 2471
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 2474
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2477
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2478
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2479
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations
Vehicle Speed Sensor: Locations
LH Side Of Engine Compartment.
Upper LH Corner Of Transaxle
Applicable to: 1989 w/Electronic Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2485
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Page 2486
Vehicle Speed Sensor: Description and Operation
The distance sensor is located in the transaxle extension housing and signals vehicle motion to the
SMEC by generating eight pulses per axle shaft revolution. The SMEC uses this signal along with
signals from the throttle position sensor to determine between a closed throttle deceleration and a
normal idle condition, thereby allowing the SMEC to maintain desired control of the AIS motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service Precautions > Customer Safety Information
Catalytic Converter: Customer Safety Information
1. On vehicles equipped with catalytic converters the following conditions must be observed;
a. Use only "UNLEADED FUEL." b. Avoid running out of fuel. c. In case of poor engine operation
(misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Avoid push
starting the vehicle.
2. Service vehicle on regular scheduled maintenance intervals to ensure proper engine
performance and lower emission levels.
3. Always be conscious of fuel odors and excessive tailpipe emission (black smoke), these are
problem indicators.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service Precautions > Customer Safety Information > Page 2492
Catalytic Converter: Technician Safety Information
ELECTRICAL AND ELECTRONIC
1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine.
2. Don't disconnect the battery when the engine is running.
3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all
insulators and shields are in place when reinstalling.
4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position
unless specifically directed to do so in a test procedure.
5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect
the secondary leads to disable the ignition system.
6. Do not use a self powered test lamp to check continuity.
7. Do not create any arcing to check the continuity of a circuit.
8. When charging battery, ensure battery cables are removed.
9. When replacing electronic components, disconnect the battery ground. NOTE: Before removing
battery ground, record stored trouble codes. ECM memory will be erased when ground cable is
removed.
10. When measuring voltage at the control unit harness connector, disconnect harness connector
first, then turn ignition "ON" as necessary.
11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead,
insert a pin from the harness side and perform measurements through pin.
12. Avoid getting water on any of the Fuel or Engine Control System Components.
13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension
cables.
14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper
adapters.
15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only,
never the lead itself.
16. Always use recommended power source in each testing procedure.
17. Never apply battery power to a component unless told to do so in a test procedure.
18. Do not try to disassemble the control unit.
19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start
engine.
20. In cases of electrical welding (for instance, spot welding), disconnect the climate control,
injection, cruise control, ECU and radio.
21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all
ECMs.
22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery.
FUEL SYSTEMS
1. Do not operate the fuel pump without fuel in the lines.
2. On fuel injected models do not depress the accelerator pedal while trying to start the car.
3. Handle all fuel injection related parts with care as they may easily be damaged.
4. Always use new gaskets or O-rings when installing fuel lines or injectors.
5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear
lubricant or brake fluid.
6. After servicing fuel system, check for leaks and correct as needed.
ENGINE AND EXHAUST
1. On vehicles equipped with catalytic converters, the following conditions must be observed:
a. Use only "UNLEADED FUEL". b. Avoid running out of fuel. c. In case of poor engine operation
(misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Do not
disconnect a spark plug wire with the engine running. e. Avoid push starting the vehicle. f.
If running on a dynamometer, make sure the catalytic converter is well ventilated.
g. Use caution when working near the catalytic converter to prevent the possibility of burns.
2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging
the sensor.
3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from
being fed to the injectors).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service Precautions > Customer Safety Information > Page 2493
Catalytic Converter: Vehicle Damage Warnings
ELECTRICAL AND ELECTRONIC
1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine.
2. Don't disconnect the battery when the engine is running.
3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all
insulators and shields are in place when reinstalling.
4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position
unless specifically directed to do so in a test procedure.
5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect
the secondary leads to disable the ignition system.
6. Do not use a self powered test lamp to check continuity.
7. Do not create any arcing to check the continuity of a circuit.
8. When charging battery, ensure battery cables are removed.
9. When replacing electronic components, disconnect the battery ground. NOTE: Before removing
battery ground, record stored trouble codes. ECM memory will be erased when ground cable is
removed.
10. When measuring voltage at the control unit harness connector, disconnect harness connector
first, then turn ignition "ON" as necessary.
11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead,
insert a pin from the harness side and perform measurements through pin.
12. Avoid getting water on any of the Fuel or Engine Control System Components.
13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension
cables.
14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper
adapters.
15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only,
never the lead itself.
16. Always use recommended power source in each testing procedure.
17. Never apply battery power to a component unless told to do so in a test procedure.
18. Do not try to disassemble the control unit.
19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start
engine.
20. In cases of electrical welding (for instance, spot welding), disconnect the climate control,
injection, cruise control, ECU and radio.
21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all
ECMs.
22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery.
FUEL SYSTEMS
1. Do not operate the fuel pump without fuel in the lines.
2. On fuel injected models do not depress the accelerator pedal while trying to start the car.
3. Handle all fuel injection related parts with care as they may easily be damaged.
4. Always use new gaskets or O-rings when installing fuel lines or injectors.
5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear
lubricant or brake fluid.
6. After servicing fuel system, check for leaks and correct as needed.
ENGINE AND EXHAUST
1. On vehicles equipped with catalytic converters, the following conditions must be observed:
a. Use only "UNLEADED FUEL". b. Avoid running out of fuel. c. In case of poor engine operation
(misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Do not
disconnect a spark plug wire with the engine running. e. Avoid push starting the vehicle. f.
If running on a dynamometer, make sure the catalytic converter is well ventilated.
g. Use caution when working near the catalytic converter to prevent the possibility of burns.
2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging
the sensor.
3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from
being fed to the injectors).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service Precautions > Page 2494
Catalytic Converter: Description and Operation
Catalytic Converter
THREE-WAY CATALYST
This catalytic converter decreases HC, CO, and NOx emissions. The catalytic converter combines
hydrocarbons (HC) and carbon monoxide (CO) with oxygen to form water (H2O) and carbon
dioxide (CO2). The three-way catalytic converter contains rhodium which reduces or separates
oxides of nitrogen (NOx) into nitrogen and oxygen. This action provides better exhaust emission
control than is obtainable by using only exhaust gas recirculation, an oxidation catalyst or engine
modifications. The three-way catalyst allows richer air/fuel mixtures, more spark advance and less
exhaust gas recirculation. All these improve both driveability and fuel economy.
Effective catalytic control of all three pollutants is possible when the correct level of CO is obtained,
and excess oxygen is reduced. Therefore, it is necessary to maintain precise control of the air/fuel
mixture entering the engine, keeping it very close to the stoichiometric point (chemically correct for
theoretical complete combustion).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service Precautions > Page 2495
Catalytic Converter: Testing and Inspection
The exhaust system should be checked for restriction before any components are replaced. Use
the following procedures for diagnosis of the exhaust system:
Check at Oxygen Sensor
1. Carefully remove O2 sensor with proper removal tool.
2. Install Exhaust Backpressure Tester in place of 02 sensor.
3. After completing test described below, be sure to coat threads of 02 sensor with antiseize
compound prior to re-installation.
Diagnosis:
1. With the engine at normal operating temperature and running at 2500 rpm, observe the exhaust
system backpressure reading on the gauge.
2. If the backpressure exceeds 1 and 1/4 psi (8.62 kPa), a restricted exhaust system is indicated.
3. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler
failure.
4. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter
should be suspected, and replaced.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light >
Component Information > Locations
Emissions Maintenance Light: Locations
Upper I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light >
Component Information > Locations > Page 2499
Emissions Maintenance Light: Service and Repair
Refer to Powertrain Management/Emission Control Systems/Service and Repair for reset
procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations
Canister Purge Solenoid: Locations
Canister Purge Solenoid
This solenoid is located in the engine compartment, above the right headlight assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 2504
Canister Purge Solenoid: Description and Operation
Fig. 9 Canister purge solenoid location
The purge solenoid, which controls both canister purge and fuel pressure regulator, Fig. 9, is
operated by the SMEC. When energized, purge vacuum is prevented from being applied to the
canister and fuel pressure is increased. Depending on data received from the charge and coolant
temperature sensors at start up, the solenoid will be energized for a controlled amount of time.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 2505
Canister Purge Solenoid: Service and Repair
1. Remove vacuum hose and electrical connector from solenoid.
2. Remove mounting fastener and remove solenoid.
3. Depress tab on top of solenoid to be replaced and slide the solenoid downward out of mounting
bracket.
3. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations
Evaporative Emission Control Canister: Locations
Charcoal Canister
The canister is located behind the right-hand headlight assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Technical Service Bulletins > Customer Interest: > 182188 > Dec > 88 > AIS Motor Erratic Idle Speed In Cold Ambients
EGR Valve: Customer Interest AIS Motor - Erratic Idle Speed In Cold Ambients
Models
1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines
Subject
Erratic Idle Speed in Cold Ambients
Index
DRIVEABILITY
Date
December 12, 1988
No.
18-21-88
(C18-26) SYMPTOM/CONDITION
Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor
failure. A revised A.I.S. motor is now available for those areas.
NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC
TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES.
PARTS REQUIRED
1987-1988 3.0L VEHICLES
1 A.I.S. Motor PN 4458366
1989 3.0L VEHICLES
1 A.I.S. Motor PN 4458355
REPAIR PROCEDURE
This repair involves replacing the A.I.S. motor with a revised A.I.S. motor.
1. Remove A.I.S. motor as outlined in the service manual.
NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO
TECHNICAL SERVICE BULLETIN 14-07-88.
2. Install new A.I.S. motor as outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.
14-30-23-93 . . . . . . . . . 0.5 Hrs.
FAILURE CODE: 61 - Intermittent Operation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for EGR Valve: > 250189 >
Sep > 89 > EGR Valve - Diagnostic Procedures Revision
EGR Valve: All Technical Service Bulletins EGR Valve - Diagnostic Procedures Revision
Models
1987-88 E, G, H, J, L, P, K & S Bodies And 1989 AA, AC, AG, AH, AJ, AK, AL, AP & AS Bodies
Subject
Revised EGR Valve Diagnostic Procedures
Index
DRIVEABILITY
Date September 18, 1989
No.
25-01-89
(C25-01-9)
P-3378 BODY CODE LEGEND
E - CARAVELLE/600/NEW YORKER TURBO
AA - SPIRIT/ACCLAIM
AC - DYNASTY/NEW YORKER/LANDAU
G/AG - DAYTONA H/AH - LANCER/LeBARON GTS (4-DOOR HATCHBACK) J/AJ - LeBARON
L/AL - OMNI/HORIZON P/AP - SHADOW/SUNDANCE K/AK - ARIES/RELIANT S/AS CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
This Technical Service Bulletin contains a revised diagnostic procedure for testing EGR valves for
a leaking poppet.
The procedure applies only to vehicles equipped with a back pressure transducer. The procedure
allows the EGR valve to be tested without removing the valve from the vehicle.
PROCEDURE
1. Turn engine off. Remove the air cleaner exposing the inlet of the throttle body. On 2.5L Turbo I
(California emissions equipped vehicles), remove the compressor outlet hose at the throttle body.
2. Disconnect the back pressure hose from the EGR valve.
3. Using a nozzle with a rubber grommet connection, direct compressed shop air (regulated to
50-60 Psi) through the steel back pressure tube on the EGR valve while opening and closing the
throttle blade.
4. If the sound from the compressed air changes distinctly while opening and closing the throttle,
the poppet is leaking and air is entering the intake manifold. Replace the EGR valve.
POLICY: For information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for EGR Valve: > 182188 >
Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients
EGR Valve: All Technical Service Bulletins AIS Motor - Erratic Idle Speed In Cold Ambients
Models
1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines
Subject
Erratic Idle Speed in Cold Ambients
Index
DRIVEABILITY
Date
December 12, 1988
No.
18-21-88
(C18-26) SYMPTOM/CONDITION
Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor
failure. A revised A.I.S. motor is now available for those areas.
NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC
TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES.
PARTS REQUIRED
1987-1988 3.0L VEHICLES
1 A.I.S. Motor PN 4458366
1989 3.0L VEHICLES
1 A.I.S. Motor PN 4458355
REPAIR PROCEDURE
This repair involves replacing the A.I.S. motor with a revised A.I.S. motor.
1. Remove A.I.S. motor as outlined in the service manual.
NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO
TECHNICAL SERVICE BULLETIN 14-07-88.
2. Install new A.I.S. motor as outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.
14-30-23-93 . . . . . . . . . 0.5 Hrs.
FAILURE CODE: 61 - Intermittent Operation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Valve: > 250189 > Sep
> 89 > EGR Valve - Diagnostic Procedures Revision
EGR Valve: All Technical Service Bulletins EGR Valve - Diagnostic Procedures Revision
Models
1987-88 E, G, H, J, L, P, K & S Bodies And 1989 AA, AC, AG, AH, AJ, AK, AL, AP & AS Bodies
Subject
Revised EGR Valve Diagnostic Procedures
Index
DRIVEABILITY
Date September 18, 1989
No.
25-01-89
(C25-01-9)
P-3378 BODY CODE LEGEND
E - CARAVELLE/600/NEW YORKER TURBO
AA - SPIRIT/ACCLAIM
AC - DYNASTY/NEW YORKER/LANDAU
G/AG - DAYTONA H/AH - LANCER/LeBARON GTS (4-DOOR HATCHBACK) J/AJ - LeBARON
L/AL - OMNI/HORIZON P/AP - SHADOW/SUNDANCE K/AK - ARIES/RELIANT S/AS CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
This Technical Service Bulletin contains a revised diagnostic procedure for testing EGR valves for
a leaking poppet.
The procedure applies only to vehicles equipped with a back pressure transducer. The procedure
allows the EGR valve to be tested without removing the valve from the vehicle.
PROCEDURE
1. Turn engine off. Remove the air cleaner exposing the inlet of the throttle body. On 2.5L Turbo I
(California emissions equipped vehicles), remove the compressor outlet hose at the throttle body.
2. Disconnect the back pressure hose from the EGR valve.
3. Using a nozzle with a rubber grommet connection, direct compressed shop air (regulated to
50-60 Psi) through the steel back pressure tube on the EGR valve while opening and closing the
throttle blade.
4. If the sound from the compressed air changes distinctly while opening and closing the throttle,
the poppet is leaking and air is entering the intake manifold. Replace the EGR valve.
POLICY: For information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Technical Service Bulletins > Page 2532
EGR Mounting
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component
Information > Description and Operation
Fillpipe Restrictor: Description and Operation
FUEL HOSES AND CLAMPS
The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may
be used as replacements. The clamps used are of a rolled edge construction to prevent cutting
hoses, and all replacements must be of this type.
NO-LEAD FILLER TUBE
All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to
prevent the addition of fuel by other than an unleaded fuel nozzle. Labels are attached at the
instrument panel and near the fuel door reading "unleaded fuel only" to remind the operator.
PRESSURE/VACUUM FILLER CAP
The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45
kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to
maintain the integrity of the fuel system.
ROLL-OVER VALVE
All fuel tanks of the closed type use a roll-over valve mounted on the top of the fuel tank. The
roll-over valve prevents fuel flow to the evaporative loss canister. In addition to the roll-over valve
there is a one way check valve mounted on the fuel return line, in the tank, which prevents fuel
from backing up into the return line from the tank. Under loss of fuel pressure conditions, or
conditions such as roll-over where tank pressure may exceed fuel return pressure, the check valve
closes, preventing fuel loss from tank.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for
Positive Crankcase Ventilation Valve: > 091689 > Oct > 89 > Engine - Oil Consumption
Positive Crankcase Ventilation Valve: Customer Interest Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for
Positive Crankcase Ventilation Valve: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2545
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Positive Crankcase Ventilation Valve: > 091689 > Oct > 89 > Engine - Oil Consumption
Positive Crankcase Ventilation Valve: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Positive Crankcase Ventilation Valve: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2551
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations
Fuel Pressure Test Port: Locations
System not equipped with fuel pressure test port. (To test fuel pressure tee into system with
adapter.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair
Fuel Pressure Release: Service and Repair
1. Loosen gas cap and allow tank pressure to release.
2. Remove wiring harness connector from any injector, then ground one injector terminal.
3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery
for approximately 10 seconds and release system pressure.
4. Remove jumper wires and service fuel system as required.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
IDLE SPEED
Idle speed adjustment is electronically controlled by the Automatic Idle Speed (AIS) Motor and is
not adjustable. For diagnosis of incorrect idle speed, refer to COMPUTERIZED ENGINE
CONTROLS.
IDLE SPEED
Automatic .............................................................................................................................................
.................................................................. 800 RPM Manual ..............................................................
...................................................................................................................................................... 800
RPM
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications > Page 2563
Idle Speed: Testing and Inspection
1. Remove air cleaner assembly, then plug heated air door vacuum hose.
2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan
cycles ON and OFF at least once. STOP engine.
3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and
ensure basic timing is set to 12° BTDC.
4. STOP engine and reconnect coolant temperature sensor wire.
5. Disconnect PCV valve hose from intake manifold nipple.
6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV
nipple.
7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1
minute.
8. Using scanner, place read/hold switch in read position and depress ATM button until code 70
appears.
9. Place read/hold switch to hold position, then the following should occur: a.
AIS motor will fully close.
b. Idle spark advance will become fixed.
c. Idle fuel will become enriched.
d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example,
display 95 equals 95 x 10 which indicates 950 rpm.
10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is
satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE
PROCEDURES. Retest minimum air flow after throttle body cleaning.
11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install
PCV valve hose.
12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door
vacuum hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications > Page 2564
Idle Speed: Adjustments
CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw.
Never attempt to adjust idle speed using this screw, unless directed to do so in a service
procedure.
Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air
Control (IAC) motor, and is not adjustable.
If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if
deposits are visible. Perform Minimum Idle Air Flow Test if applicable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Adjustments
Air/Fuel Mixture: Adjustments
CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw.
Never attempt to adjust idle mixture using this screw!
Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not
adjustable.
If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE
Computers and Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients
Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins AIS Motor - Erratic Idle Speed In
Cold Ambients
Models
1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines
Subject
Erratic Idle Speed in Cold Ambients
Index
DRIVEABILITY
Date
December 12, 1988
No.
18-21-88
(C18-26) SYMPTOM/CONDITION
Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor
failure. A revised A.I.S. motor is now available for those areas.
NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC
TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES.
PARTS REQUIRED
1987-1988 3.0L VEHICLES
1 A.I.S. Motor PN 4458366
1989 3.0L VEHICLES
1 A.I.S. Motor PN 4458355
REPAIR PROCEDURE
This repair involves replacing the A.I.S. motor with a revised A.I.S. motor.
1. Remove A.I.S. motor as outlined in the service manual.
NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO
TECHNICAL SERVICE BULLETIN 14-07-88.
2. Install new A.I.S. motor as outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.
14-30-23-93 . . . . . . . . . 0.5 Hrs.
FAILURE CODE: 61 - Intermittent Operation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 182188 >
Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients
Auxiliary Air Valve (Idle Speed): Customer Interest AIS Motor - Erratic Idle Speed In Cold Ambients
Models
1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines
Subject
Erratic Idle Speed in Cold Ambients
Index
DRIVEABILITY
Date
December 12, 1988
No.
18-21-88
(C18-26) SYMPTOM/CONDITION
Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor
failure. A revised A.I.S. motor is now available for those areas.
NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC
TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES.
PARTS REQUIRED
1987-1988 3.0L VEHICLES
1 A.I.S. Motor PN 4458366
1989 3.0L VEHICLES
1 A.I.S. Motor PN 4458355
REPAIR PROCEDURE
This repair involves replacing the A.I.S. motor with a revised A.I.S. motor.
1. Remove A.I.S. motor as outlined in the service manual.
NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO
TECHNICAL SERVICE BULLETIN 14-07-88.
2. Install new A.I.S. motor as outlined in the service manual.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.
14-30-23-93 . . . . . . . . . 0.5 Hrs.
FAILURE CODE: 61 - Intermittent Operation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component
Information > Description and Operation
Fillpipe Restrictor: Description and Operation
FUEL HOSES AND CLAMPS
The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may
be used as replacements. The clamps used are of a rolled edge construction to prevent cutting
hoses, and all replacements must be of this type.
NO-LEAD FILLER TUBE
All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to
prevent the addition of fuel by other than an unleaded fuel nozzle. Labels are attached at the
instrument panel and near the fuel door reading "unleaded fuel only" to remind the operator.
PRESSURE/VACUUM FILLER CAP
The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45
kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to
maintain the integrity of the fuel system.
ROLL-OVER VALVE
All fuel tanks of the closed type use a roll-over valve mounted on the top of the fuel tank. The
roll-over valve prevents fuel flow to the evaporative loss canister. In addition to the roll-over valve
there is a one way check valve mounted on the fuel return line, in the tank, which prevents fuel
from backing up into the return line from the tank. Under loss of fuel pressure conditions, or
conditions such as roll-over where tank pressure may exceed fuel return pressure, the check valve
closes, preventing fuel loss from tank.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 18-05-97 > Feb > 97 > Engine - Driveway Die
Out/Rough Idle/Low Power
Fuel: All Technical Service Bulletins Engine - Driveway Die Out/Rough Idle/Low Power
NO: 18-05-97
GROUP: Vehicle Performance
DATE: Feb. 14, 1997
SUBJECT: Intake Valve Deposits
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-16-93, DATED NOV. 12,
1993 AND 18-20-94, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR
FILES AND NOTED IN THE 1993 AND 1994 TECHNICAL SERVICE BULLETIN MANUALS
(PUBLICATION NO's. 81-699-94000 AND 81-699-95054). ALL REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS** AND INCLUDE MODEL AND APPLICATION CHANGES.
MODELS:
**1989 - 1995** (AA) Spirit/Acclaim/LeBaron Sedan
**1988 - 1993** (AC) Dynasty/New Yorker Salon
**1990 - 1994** (AG) Daytona
**1990 - 1995** (AJ) LeBaron Coupe/LeBaron Convertible
**1992 - 1994** (AP) Shadow/Shadow Convertible/Sundance
**1987 - 1995** (AS) Town & Country/Caravan/Voyager
**1996 - 1997** (NS) Town & Country/Caravan/Voyager
**NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L ENGINE.**
SYMPTOM/CONDITION:
Driveway die out, rough idle, lack of power, sags, and hesitation.
DISCUSSION:
The above conditions may be the result of a build up of deposits on the back of the intake valves
causing blockage of fuel delivery into the upper combustion chamber. This blockage results in fuel
starvation. The deposits can be the result of fuel blending methods that have insufficient or
ineffective fuel detergent additives.
Fuel quality is a direct result of the crude oil used, the refinement process, the storage, delivery and
distribution methods, and the blending of additive compounds. Using fuel with a higher posted
octane number does not guarantee high quality, or that it is blended with adequate or effective
detergent, corrosion inhibitors, or additives. Gasoline/Oxygenate blends which use unleaded
gasoline and compounds that contain oxygen, such as alcohol, ethanol, MTBE, and ETBE may not
indicate that adequate or effective detergent additives are available either.
Gasoline Companies acknowledge that fuel quality is important. A number of them advertise, as
well as warrant their fuel is blended to contain the necessary additives for efficient and clean
operation of modern vehicles. Fuels available from these companies should be considered to
assure full performance and clean operation.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed.
If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as
necessary before proceeding further with this bulletin. If no DTC's are present, make sure the PCM
is at the latest software version.
If all systems are functioning as designed, ask the customer about the fuel that is being used in the
vehicle. If there is a question about the quality of the fuel, suggest that only fuels be used that are
warranted by the gasoline company against the build up of deposits.
REPAIR PROCEDURE:
Depending on the amount of deposit on the valves, there are several methods that can be used to
remove them.
1. The use of Mopar Fuel Injector Cleaner has shown reasonable results on light deposits. Add one
bottle of Mopar Fuel Injector Cleaner, p/n 4318007, to a full tank of gas.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 18-05-97 > Feb > 97 > Engine - Driveway Die
Out/Rough Idle/Low Power > Page 2592
CAUTION:
UNDER NO CIRCUMSTANCES SHOULD THIS FUEL INJECTOR CLEANER BE ADDED TO A
PARTIALLY FILLED FUEL TANK.
Mopar Fuel Injector Cleaner will remove light deposits that have built up over a period of time.
However, it is not intended for continuous use. Owners should be advised of the cause of their
driveability concern and a recommendation should be made to try other brands of fuel.
2. For moderate to heavy deposits, the intake valves should be cleaned. The suggested method for
cleaning involves removal of the cylinder head from the engine. The head must be disassembled,
and the carbon removed from the valves and surrounding components with a wire brush.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Customer Interest for Fuel: > 18-05-97 > Feb > 97 > Engine - Driveway Die Out/Rough
Idle/Low Power
Fuel: Customer Interest Engine - Driveway Die Out/Rough Idle/Low Power
NO: 18-05-97
GROUP: Vehicle Performance
DATE: Feb. 14, 1997
SUBJECT: Intake Valve Deposits
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-16-93, DATED NOV. 12,
1993 AND 18-20-94, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR
FILES AND NOTED IN THE 1993 AND 1994 TECHNICAL SERVICE BULLETIN MANUALS
(PUBLICATION NO's. 81-699-94000 AND 81-699-95054). ALL REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS** AND INCLUDE MODEL AND APPLICATION CHANGES.
MODELS:
**1989 - 1995** (AA) Spirit/Acclaim/LeBaron Sedan
**1988 - 1993** (AC) Dynasty/New Yorker Salon
**1990 - 1994** (AG) Daytona
**1990 - 1995** (AJ) LeBaron Coupe/LeBaron Convertible
**1992 - 1994** (AP) Shadow/Shadow Convertible/Sundance
**1987 - 1995** (AS) Town & Country/Caravan/Voyager
**1996 - 1997** (NS) Town & Country/Caravan/Voyager
**NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L ENGINE.**
SYMPTOM/CONDITION:
Driveway die out, rough idle, lack of power, sags, and hesitation.
DISCUSSION:
The above conditions may be the result of a build up of deposits on the back of the intake valves
causing blockage of fuel delivery into the upper combustion chamber. This blockage results in fuel
starvation. The deposits can be the result of fuel blending methods that have insufficient or
ineffective fuel detergent additives.
Fuel quality is a direct result of the crude oil used, the refinement process, the storage, delivery and
distribution methods, and the blending of additive compounds. Using fuel with a higher posted
octane number does not guarantee high quality, or that it is blended with adequate or effective
detergent, corrosion inhibitors, or additives. Gasoline/Oxygenate blends which use unleaded
gasoline and compounds that contain oxygen, such as alcohol, ethanol, MTBE, and ETBE may not
indicate that adequate or effective detergent additives are available either.
Gasoline Companies acknowledge that fuel quality is important. A number of them advertise, as
well as warrant their fuel is blended to contain the necessary additives for efficient and clean
operation of modern vehicles. Fuels available from these companies should be considered to
assure full performance and clean operation.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed.
If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as
necessary before proceeding further with this bulletin. If no DTC's are present, make sure the PCM
is at the latest software version.
If all systems are functioning as designed, ask the customer about the fuel that is being used in the
vehicle. If there is a question about the quality of the fuel, suggest that only fuels be used that are
warranted by the gasoline company against the build up of deposits.
REPAIR PROCEDURE:
Depending on the amount of deposit on the valves, there are several methods that can be used to
remove them.
1. The use of Mopar Fuel Injector Cleaner has shown reasonable results on light deposits. Add one
bottle of Mopar Fuel Injector Cleaner, p/n 4318007, to a full tank of gas.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Customer Interest for Fuel: > 18-05-97 > Feb > 97 > Engine - Driveway Die Out/Rough
Idle/Low Power > Page 2598
CAUTION:
UNDER NO CIRCUMSTANCES SHOULD THIS FUEL INJECTOR CLEANER BE ADDED TO A
PARTIALLY FILLED FUEL TANK.
Mopar Fuel Injector Cleaner will remove light deposits that have built up over a period of time.
However, it is not intended for continuous use. Owners should be advised of the cause of their
driveability concern and a recommendation should be made to try other brands of fuel.
2. For moderate to heavy deposits, the intake valves should be cleaned. The suggested method for
cleaning involves removal of the cylinder head from the engine. The head must be disassembled,
and the carbon removed from the valves and surrounding components with a wire brush.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Page 2599
Fuel: Specifications
GASOLINE:
Unleaded gasoline must be used with all engines. Premium unleaded fuel 92 octane is not
recommended.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
1. Loosen gas cap and allow tank pressure to release.
2. Remove wiring harness connector from any injector, then ground one injector terminal.
3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery
for approximately 10 seconds and release system pressure.
4. Remove jumper wires and service fuel system as required.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors Long Crank Time to Start
Fuel Injector: Customer Interest Fuel Injectors - Long Crank Time to Start
Models
1983-1990 S/AS Body, 1988-1990 C/AC Body, 1989-90 AA-Body and 1990 AG and AJ Bodies
With 3.0L Engine
Subject
Long Crank Time Before Starting Leaking Fuel Injectors
Index
DRIVEABILITY
Date
December 22, 1989
No.
18-11-89 REVISION A
(C18-29-9)
P-4406 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM/LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
AG - DAYTONA
AJ - LEBARON (COUPE/CONVERTIBLE)
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-11-89, Dated 8/21/89,
WHICH SHOULD BE REMOVED FROM YOUR FILES.
SYMPTOM/CONDITION
As vehicle mileage accumulates, the owner may notice that the vehicle has longer crank time (3
seconds or longer) before starting. This could occur after either cold or hot soak periods. If the
customer complaint is long crank time, use the following procedure. Do not use any other
diagnostic tests.
PARTS REQUIRED
2 Plenum Gaskets PN MD094128
1 EGR Gasket (for '87 & '88) PN MD103625
1 Vacuum Tee (1/4 x 1/4 x 1/4) PN 4306994*
1 Vacuum Connector (1/4 x 1/4) PN 4201275*
*NOTE: THESE COMPONENTS ARE REUSABLE AND CAN BE USED FOR
TESTING OF SUBSEQUENT VEHICLES. THE EXACT VACUUM TEE AND VACUUM
CONNECTOR MUST BE USED FOR THIS TEST. THE USE OF OTHER SIZE TEES OR
CONNECTORS WILL RESULT IN INVALID TEST RESULTS. ALL OTHER EQUIPMENT MUST
BE USED AS SPECIFIED.
REPAIR PROCEDURE
This procedure outlines the diagnosis of leaking fuel injectors, which may cause long crank time
before starting.
1. Start and run engine until it reaches operating temperature. Wait until radiator fan cycles twice,
then turn off engine. This procedure must be performed while the engine is at normal operating
temperature.
2. Remove shop exhaust hose from tailpipe, if it was connected during engine warm-up.
3. Remove air inlet duct to the throttle body. Remove throttle linkage. On 1987 and 1988 vehicles,
remove the EGR tube attached to the intake plenum. Remove top of intake plenum.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors Long Crank Time to Start > Page 2612
4. Using compressed air, blow out the intake manifold runners for EXACTLY FIVE (5) SECONDS
EACH.
5. Remove coil ignition cable from distributor cap and attach to a good ground.
6. Use the DRB II to actuate fuel pump to pressurize the fuel system (for 1987 and 1988 vehicles
use ATM mode 01 "coil spark," and for 1989 and 1990 vehicles use ATM "ignition coil"). Keep ATM
activated for one minute (MUST BE EXACTLY ONE MINUTE) then exit ATM.
7. Obtain a 5-foot long section of 1/4" I.D. rubber hose (MUST BE EXACTLY 5 FEET OF 1/4" I.D.
HOSE) to be used as an air sample line connected to a hydrocarbon exhaust gas analyzer. Make
sure that the exhaust gas analyzer has a clean filter and is calibrated before performing this test.
FIGURE 1
8. Install vacuum connector (PN 4201275) in the sample line at the end to be inserted into the
intake manifold runner. Install vacuum tee (PN 4306994) at EXACTLY the middle of the sample
line so that fresh air will be drawn in (see Figure 1).
FIGURE 2
9. Wait for EXACTLY FIVE (5) MINUTES after exiting ATM, and then, one by one, insert the
sample line approximately 5-6" down into each intake manifold runner (MARK THE HOSE WITH A
PIECE OF TAPE SO THAT THE HOSE IS INSERTED EXACTLY THE SAME DISTANCE INTO
EACH RUNNER). Record the peak HC (hydrocarbon) reading for each intake runner, being sure to
let the analyzer reset to zero (0) before taking the next reading.
NOTE: THE INTAIKE MANIFOLD IS A CROSSOVER DESIGN. THEREFORE, TO TAKE
READINGS FOR CYLINDERS 2, 4, AND 6 (WHICH ARE NEAREST THE FRONT OF THE
VEHICLE), THE REAR MANIFOID RUNNERS MUST BE CHECKED (FIGURE 2).
10. After taking the readings from each intake runner, replace that cylinder's fuel injector only if HC
readings are 100 ppm or greater.
11. Reinstall intake manifold plenum and torque bolts to 13 N-m (115 in.lbs.). On 1987 and 1988
vehicles, reinstall EGR tube to intake plenum and torque to 22 N-m (200 in.lbs.)
12. Reinstall the throttle cables and air inlet duct.
13. Reinstall coil ignition cable to distributor cap.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: EFFECTIVE JANUARY 1, 1990
Labor Operation No. 14-30-20-68 . . . . . . . . . . . 0.3 Hrs.
(Injector Infra-Red Test)
14-30-20-23 . . . . . . . . . . . 0.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors Long Crank Time to Start > Page 2613
(Replace 1 to 3 Injectors)
14-30-20-24 . . . . . . . . . . . 1.1 Hrs.
(Replace 4 to 6 Injectors)
FAILURE CODE: 43 - Fuel Leaks
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 181189A > Dec > 89 > Fuel
Injectors - Long Crank Time to Start
Fuel Injector: All Technical Service Bulletins Fuel Injectors - Long Crank Time to Start
Models
1983-1990 S/AS Body, 1988-1990 C/AC Body, 1989-90 AA-Body and 1990 AG and AJ Bodies
With 3.0L Engine
Subject
Long Crank Time Before Starting Leaking Fuel Injectors
Index
DRIVEABILITY
Date
December 22, 1989
No.
18-11-89 REVISION A
(C18-29-9)
P-4406 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM/LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
AG - DAYTONA
AJ - LEBARON (COUPE/CONVERTIBLE)
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-11-89, Dated 8/21/89,
WHICH SHOULD BE REMOVED FROM YOUR FILES.
SYMPTOM/CONDITION
As vehicle mileage accumulates, the owner may notice that the vehicle has longer crank time (3
seconds or longer) before starting. This could occur after either cold or hot soak periods. If the
customer complaint is long crank time, use the following procedure. Do not use any other
diagnostic tests.
PARTS REQUIRED
2 Plenum Gaskets PN MD094128
1 EGR Gasket (for '87 & '88) PN MD103625
1 Vacuum Tee (1/4 x 1/4 x 1/4) PN 4306994*
1 Vacuum Connector (1/4 x 1/4) PN 4201275*
*NOTE: THESE COMPONENTS ARE REUSABLE AND CAN BE USED FOR
TESTING OF SUBSEQUENT VEHICLES. THE EXACT VACUUM TEE AND VACUUM
CONNECTOR MUST BE USED FOR THIS TEST. THE USE OF OTHER SIZE TEES OR
CONNECTORS WILL RESULT IN INVALID TEST RESULTS. ALL OTHER EQUIPMENT MUST
BE USED AS SPECIFIED.
REPAIR PROCEDURE
This procedure outlines the diagnosis of leaking fuel injectors, which may cause long crank time
before starting.
1. Start and run engine until it reaches operating temperature. Wait until radiator fan cycles twice,
then turn off engine. This procedure must be performed while the engine is at normal operating
temperature.
2. Remove shop exhaust hose from tailpipe, if it was connected during engine warm-up.
3. Remove air inlet duct to the throttle body. Remove throttle linkage. On 1987 and 1988 vehicles,
remove the EGR tube attached to the intake plenum. Remove top of intake plenum.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 181189A > Dec > 89 > Fuel
Injectors - Long Crank Time to Start > Page 2619
4. Using compressed air, blow out the intake manifold runners for EXACTLY FIVE (5) SECONDS
EACH.
5. Remove coil ignition cable from distributor cap and attach to a good ground.
6. Use the DRB II to actuate fuel pump to pressurize the fuel system (for 1987 and 1988 vehicles
use ATM mode 01 "coil spark," and for 1989 and 1990 vehicles use ATM "ignition coil"). Keep ATM
activated for one minute (MUST BE EXACTLY ONE MINUTE) then exit ATM.
7. Obtain a 5-foot long section of 1/4" I.D. rubber hose (MUST BE EXACTLY 5 FEET OF 1/4" I.D.
HOSE) to be used as an air sample line connected to a hydrocarbon exhaust gas analyzer. Make
sure that the exhaust gas analyzer has a clean filter and is calibrated before performing this test.
FIGURE 1
8. Install vacuum connector (PN 4201275) in the sample line at the end to be inserted into the
intake manifold runner. Install vacuum tee (PN 4306994) at EXACTLY the middle of the sample
line so that fresh air will be drawn in (see Figure 1).
FIGURE 2
9. Wait for EXACTLY FIVE (5) MINUTES after exiting ATM, and then, one by one, insert the
sample line approximately 5-6" down into each intake manifold runner (MARK THE HOSE WITH A
PIECE OF TAPE SO THAT THE HOSE IS INSERTED EXACTLY THE SAME DISTANCE INTO
EACH RUNNER). Record the peak HC (hydrocarbon) reading for each intake runner, being sure to
let the analyzer reset to zero (0) before taking the next reading.
NOTE: THE INTAIKE MANIFOLD IS A CROSSOVER DESIGN. THEREFORE, TO TAKE
READINGS FOR CYLINDERS 2, 4, AND 6 (WHICH ARE NEAREST THE FRONT OF THE
VEHICLE), THE REAR MANIFOID RUNNERS MUST BE CHECKED (FIGURE 2).
10. After taking the readings from each intake runner, replace that cylinder's fuel injector only if HC
readings are 100 ppm or greater.
11. Reinstall intake manifold plenum and torque bolts to 13 N-m (115 in.lbs.). On 1987 and 1988
vehicles, reinstall EGR tube to intake plenum and torque to 22 N-m (200 in.lbs.)
12. Reinstall the throttle cables and air inlet duct.
13. Reinstall coil ignition cable to distributor cap.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: EFFECTIVE JANUARY 1, 1990
Labor Operation No. 14-30-20-68 . . . . . . . . . . . 0.3 Hrs.
(Injector Infra-Red Test)
14-30-20-23 . . . . . . . . . . . 0.9 Hrs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 181189A > Dec > 89 > Fuel
Injectors - Long Crank Time to Start > Page 2620
(Replace 1 to 3 Injectors)
14-30-20-24 . . . . . . . . . . . 1.1 Hrs.
(Replace 4 to 6 Injectors)
FAILURE CODE: 43 - Fuel Leaks
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Page 2621
Fuel Injector: Locations
Fuel Injectors And Rail Assembly
The 6 fuel injectors are found attached to the fuel rail, mounted under the intake plenum. The
plenum must be removed to access the fuel injectors.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Page 2622
Fuel Injector: Description and Operation
Fig. 7 Fuel injector
The fuel injector, Fig. 7, is a solenoid operated valve which is energized and controlled by the
SMEC. When voltage is applied to the injector solenoid, a spring loaded ball is lifted off its seat and
fuel is sprayed into the combustion chamber through spray orifices. The spray orifices and injector
tip design cause the fuel to be sprayed in an even conical pattern prior to entering the intake air
stream. The amount of fuel delivered by the injector is determined by the amount of time that the
injector solenoid is energized. The SMEC determines the amount of fuel necessary to maintain
ideal air/fuel mixtures based upon various sensor inputs. The SMEC then energizes the fuel
injector for a sufficient amount of time to deliver the necessary amount of fuel.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Page 2623
Fuel Injector: Testing and Inspection
NOTE: Make sure injectors have been cleaned with an approved cleaner prior to testing. The
injector balance test is done to verify a balanced distribution of fuel to all cylinders.
1. Start by hooking up a fuel pressure gauge at the schrader valve or inline before the fuel pressure
regulator (refer to gauge manufacturer instructions).
2. Pressurize the fuel rail by turning ignition to ON position, and energizing the fuel pump by
selecting ASD in the ATM test mode with the DRB II or equivalent scanner. Fuel pressure should
rise to maximum working pressure. Refer to SPECIFICATIONS.
3. Remove injector harness connector and connect an injector pulse tester.
4. Pulse one injector at a time. Allow pressure to rise and stabilize in between each injector tested.
NOTE: The time each injector is pulsed is very important. Each injector should be pulsed at the
same time interval, (example..1 ms each).
5. The rate of drop should be even across all the injectors. All pressure drops should be within 3%
of each other, if not replace injector.
6. If there is no pressure drop when injector is pulsed, verify there is a good connection between
the injector and pulse tester. If connection is good, a check of the injector circuit is required.
7. First, check the resistance of the injector, if resistance is OK verify there is power to injector by
reconnecting the injector harness connector and START engine.
8. Use a "NOID" light to check for pulses (light off and on). If it does not light this is an indication of
a problem in the injector to SMEC circuit. Refer to COMPUTERIZED ENGINE CONTROLS for
further testing. If light pulses, recheck pressure drop to verify malfunction. NOTE: It may not be
possible to connect a noid light to the harness while connected to injector. If this is the case
disconnect harness and connect noid light to harness and check pulses.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Fuel Injector Cleaning Procedure
Fuel Injector: Service and Repair Fuel Injector Cleaning Procedure
PROCEDURE:
1. Fuel system pressure must be released prior to service, refer to FUEL SYSTEM PRESSURE
RELEASE.
2. Disconnect the fuel supply line from the inlet side of the fuel rail.
3. Attach the fuel supply line to the return line.
4. Plug the fuel return fitting at the fuel rail, or connect to tester/cleaner depending on configuration.
5. Connect the fuel supply hose from the tester/cleaner to the fuel supply manifold.
6. Turn the tester/cleaner ON. (Tester/cleaner should run 10 minutes.)
7. START the engine and check the fuel lines for leakage. If there is any sign of leakage, turn the
vehicle and the tester/cleaner OFF and repair the location where fuel is leaking. Then return to
Step 6.
8. When the engine speed has stabilized, set the idle speed at 2000 rpm. Run the remainder of the
10 minute cycle to eliminate all the air in the fuel supply hose and fuel rail.
9. Turn power switch OFF and disconnect power lines.
10. Disconnect cleaner supply hose from the fuel supply manifold.
11. Connect vehicle fuel lines. START engine and check for leaks. Lubricate O-rings prior to
installation and ensure fuel lines are securely connected.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 2626
Fuel Injector: Service and Repair Fuel Injector Replacement
Fuel Injector
REMOVAL
1. Fuel system pressure release must be performed prior to service. Refer to MAINTENANCE
PROCEDURES.
2. Fuel rail must be removed prior to servicing fuel injectors.
3. Disconnect the wiring connector from the fuel rail to the injector.
4. Remove the fuel injector lock clip, and slide the injector straight out of the fuel rail cup.
5. Check each injector O-ring for damage and replace any damaged O-rings prior to reinstallation.
If the injector is to be re-used, place a protective cap over the injector tip, while it is removed.
INSTALLATION
1. Before installing injectors lubricate the O-ring with a drop of engine oil.
2. Install injector top into fuel rail cup.
3. Install injector lock clip by sliding open end into injector slot, and onto the fuel rail cup side slots.
4. Install injector electrical connector.
5. Perform fuel system pressure test to check for leaks, refer to DIAGNOSIS AND TESTING/FUEL
SYSTEM DIAGNOSIS for procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations
Fuel Pressure Regulator: Locations
Fuel Pressure Regulator
The fuel pressure regulator is mounted to the fuel rail assembly at the opposite end from the fuel
inlet line. The intake plenum must be removed to access the fuel pressure regulator.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 2630
Fuel Pressure Regulator: Description and Operation
Fuel Pressure Regulator
The fuel pressure regulator is used to maintain a constant pressure differential at the fuel injector
tip of 48 psi. The pressure regulator uses a vacuum assisted spring loaded diaphragm to control
the fuel return port in order to maintain constant pressure. Pressurized fuel is delivered first to the
fuel injector and then flows to the pressure regulator. When fuel pressure acting on the regulator
diaphragm exceeds 48 psi, the regulator spring is compressed and the fuel return port is opened.
When fuel pressure drops below 48 psi, spring tension causes the diaphragm to block the fuel
return port. As manifold vacuum increases during deceleration, less pressure is needed to supply
the same amount of fuel into the air flow. In order to fine tune the fuel pressure under all operating
conditions, the vacuum assists in opening the fuel port during high vacuum conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Service and Repair > Fuel Pressure Regulator Replacement
Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator Replacement
Fuel Pressure Regulator
REMOVAL
1. Fuel system pressure must be released prior to service. Refer to MAINTENANCE
PROCEDURES.
2. The fuel rail must be removed prior to fuel pressure regulator service, refer to FUEL RAIL for
removal procedure.
3. Remove 2 attaching bolts and remove fuel pressure regulator from fuel rail. Inspect O-ring for
damage or wear and replace if necessary.
4. Loosen and remove fuel return hose.
INSTALLATION
1. Lube fuel pressure O-ring with clean engine oil prior to reinstallation. Press regulator into fuel rail
and attach 2 mounting bolts. Torque to 8.7 Nm (77 lb-in).
2. Install fuel return hose and torque to 1 Nm (10 lb-in).
3. After reinstallation of fuel rail and all other components perform fuel pressure test to check for
leaks. Refer to Powertrain Management/Fuel Delivery and Air Induction/Testing and
Inspection/Procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Service and Repair > Fuel Pressure Regulator Replacement > Page 2633
Fuel Pressure Regulator: Service and Repair Fuel Rail Assembly & Fuel Pressure Regulator
Fig. 14 Removing fuel pressure regulator hose
1. Perform fuel system pressure release procedure.
2. Disconnect battery ground cable.
3. Disconnect air cleaner to throttle body hose.
4. Disconnect throttle cable and kick down linkage from throttle body.
5. Disconnect vacuum hoses and electrical connectors from throttle body.
6. Disconnect PCV and brake booster hoses from air intake plenum.
7. Remove EGR tube flange from air intake plenum.
8. Disconnect electrical connectors from charge and coolant temperature sensors.
9. Disconnect vacuum hose connections from air intake plenum.
10. Disconnect fuel hoses from fuel rail.
11. Remove eight bolts attaching air intake plenum to intake manifold, then remove air intake
plenum.
12. Disconnect vacuum hoses from fuel rail and fuel pressure regulator, Fig. 14.
13. Disconnect fuel injector wiring harness from engine wiring harness.
14. Remove fuel pressure regulator attaching bolts, then loosen hose clamps and remove
regulator.
15. Remove fuel rail attaching bolts, then carefully rail assembly from intake manifold.
16. Reverse procedure to install and note the following: a. Prior to installation lubricate O-rings with
a drop clean engine oil. b. Ensure injectors are seated in receiver cup with lock ring. c. Ensure
injectors are fully seated in ports. d. Torque fuel rail attaching bolts to 115 inch lbs. e. Torque fuel
pressure regulator attaching bolts to 95 inch lbs. f.
Prior to starting engine check all hoses and electrical connectors for proper connection.
g. After completing installation, check system for leaks.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Locations
Fuel Pressure Test Port: Locations
System not equipped with fuel pressure test port. (To test fuel pressure tee into system with
adapter.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
Fuel Pressure Test Port > Component Information > Locations
Fuel Pressure Test Port: Locations
System not equipped with fuel pressure test port. (To test fuel pressure tee into system with
adapter.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Fuel Pump Relay: Locations
Engine Compartment Components
This vehicle utilizes the Automatic Shutdown (ASD) Relay to control the Fuel Pump operation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations
Fuel Rail: Locations
Fuel Injectors And Rail Assembly
The fuel rail assembly is mounted beneath the intake plenum, on top of the engine. The intake
plenum must be removed to access the fuel rail.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations > Page 2648
Fuel Rail: Description and Operation
Fuel Injectors And Rail Assembly
The fuel rail is a steel distribution pipe with mounting points for the fuel pressure regulator, 6 fuel
injectors, and injector wire harness. The fuel rail performs the dual functions of fuel supply to the
injection components, and providing the necessary brackets and fittings to mount the components
to the engine. Fuel enters the fuel rail at the inlet tube, proceeds to the 6 fuel injectors, then to the
fuel pressure regulator, and returns to the tank through the fuel pressure regulator. The fuel rail is
under constant fuel pressure and fuel pressure release is required prior to servicing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations > Page 2649
Fuel Rail: Service and Repair
REMOVAL
1. Fuel system pressure must be released prior to service. Refer to MAINTENANCE
PROCEDURES.
2. Disconnect negative battery terminal, and remove air cleaner to throttle body hose.
Throttle Cable Auto Transaxle
3. Remove throttle cable and transaxle kickdown linkage.
Throttle Body Connections
4. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors
from throttle body. Remove vacuum hose harness from throttle body, and remove PCV and brake
booster hoses from air intake plenum.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Locations > Page 2650
Coolant Temperature Sensor Connections
5. Remove wiring connector from coolant temperature sensor. Remove vacuum connections from
air intake plenum vacuum connector. Remove fuel hoses from fuel rail.
Intake Plenum Removal
6. Remove all 8 fasteners from air intake plenum and remove plenum from intake manifold. Cover
intake manifold ports before proceeding.
7. Disconnect fuel injector harness from engine harness. Remove fuel pressure regulator attaching
bolts. Remove fuel pressure regulator from rail. Check fuel pressure regulator O-ring for damage or
wear and replace as necessary.
8. Remove fuel rail mounting bolts and lift fuel rail assembly from intake manifold, using care to
avoid damaging injectors or injector O-rings.
INSTALLATION
1. Make sure injectors are seated into fuel rail receiver cups, and injector lock clips are in place.
Check injector holes to make sure they are clean and any plugs have been removed. Lube injector
O-rings with clean engine oil prior to installation.
2. Place the tip of each injector in its respective port and push the rail assembly into place until all
injectors are seated in the ports. Install the fuel rail attaching bolts and torque to 13 Nm (115 lb-in).
3. Lube fuel pressure regulator O-ring with clean engine oil, and install fuel pressure regulator onto
fuel rail. Install mounting bolts and torque to 8.7 Nm (77 lb-in). Install fuel pressure regulator hoses
and clamps and torque to 1 Nm (10 lb-in).
4. Connect fuel injector wiring harness to engine wiring harness, and connect vacuum harness to
fuel rail assembly. Remove covering from intake manifold, and clean surface.
5. Place intake manifold gaskets on lower manifold, with beaded sealer up. Install intake plenum
and torque fasteners to 13 Nm (115 lb-in).
6. Connect fuel inlet line to fuel rail and torque clamp to 1 Nm (10 lb-in). Connect vacuum harness
to air intake plenum and fuel pressure regulator. Connect coolant temperature sensor electrical
connector to sensor.
7. Connect brake booster supply hose to intake plenum and connect PCV hose to plenum. Connect
AIS motor and TPS, and connect vacuum vapor harness to throttle body.
8. Install throttle cable, and air inlet hose assembly. Connect negative battery terminal.
9. Pressurize fuel system and check for leaks. Refer to DIAGNOSIS AND TESTING/FUEL
SYSTEM DIAGNOSIS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component
Information > Description and Operation
Fuel Reservoir: Description and Operation
An electric fuel pump is located in a specially designed reservoir within the fuel tank. The reservoir
ensures that fuel is available at the pump inlet during all operating conditions, particularly when
little fuel remains in the tank. The fuel pump is energized by the ASD relay and operates whenever
the relay is activated. Fuel is drawn into the pump through a `sock type' filter screen, and the pump
contains an integral fuel inlet check valve to prevent drain back.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Locations
Fuel Return Line: Locations
Fuel Tank Filter And Hose Location
The fuel tank is found in the rear of the vehicle, lines and hoses are typically routed along the right
(passenger) frame rail.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Locations > Page 2657
Fuel Return Line: Description and Operation
FUEL HOSES AND CLAMPS
The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may
be used as replacements. The clamps used are of a rolled edge construction to prevent cutting
hoses, and all replacements must be of this type.
NO-LEAD FILLER TUBE
All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to
prevent the addition of fuel by other than an unleaded fuel nozzle. Labels are attached at the
instrument panel and near the fuel door reading "unleaded fuel only" to remind the operator.
PRESSURE/VACUUM FILLER CAP
The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45
kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to
maintain the integrity of the fuel system.
ROLL-OVER VALVE
All fuel tanks of the closed type use a roll-over valve mounted on the top of the fuel tank. The
roll-over valve prevents fuel flow to the evaporative loss canister. In addition to the roll-over valve
there is a one way check valve mounted on the fuel return line, in the tank, which prevents fuel
from backing up into the return line from the tank. Under loss of fuel pressure conditions, or
conditions such as roll-over where tank pressure may exceed fuel return pressure, the check valve
closes, preventing fuel loss from tank.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Locations
Fuel Supply Line: Locations
Fuel Tank Filter And Hose Location
The fuel tank is found in the rear of the vehicle, lines and hoses are typically routed along the right
(passenger) frame rail.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Locations > Page 2661
Fuel Supply Line: Description and Operation
FUEL HOSES AND CLAMPS
The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may
be used as replacements. The clamps used are of a rolled edge construction to prevent cutting
hoses, and all replacements must be of this type.
NO-LEAD FILLER TUBE
All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to
prevent the addition of fuel by other than an unleaded fuel nozzle. Labels are attached at the
instrument panel and near the fuel door reading "unleaded fuel only" to remind the operator.
PRESSURE/VACUUM FILLER CAP
The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45
kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to
maintain the integrity of the fuel system.
ROLL-OVER VALVE
All fuel tanks of the closed type use a roll-over valve mounted on the top of the fuel tank. The
roll-over valve prevents fuel flow to the evaporative loss canister. In addition to the roll-over valve
there is a one way check valve mounted on the fuel return line, in the tank, which prevents fuel
from backing up into the return line from the tank. Under loss of fuel pressure conditions, or
conditions such as roll-over where tank pressure may exceed fuel return pressure, the check valve
closes, preventing fuel loss from tank.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Locations
Fuel Filler Hose: Locations
Fuel Tank Filter And Hose Location
The fuel tank is found in the rear of the vehicle, lines and hoses are typically routed along the right
(passenger) frame rail.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Locations
Fuel Gauge Sender: Locations
Top Of Fuel Tank
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Locations > Page 2669
Fuel Gauge Sender: Testing and Inspection
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit.
1. Disconnect wiring from fuel tank sending unit. 2. Connect wiring to a known good sending unit. 3.
Connect a jumper wire between sending unit pick up tube and ground.
Fuel Tank Sending Unit (Typical)
4. Check fuel gauge as follows: Allow at least two minutes for gauge to settle at each test point.
a. Move and clip float arm to its empty stop and turn ignition to the On position, gauge should read
Empty or below. b. Move and clip float arm to the Full position, gauge should read Full or above.
5. If gauge does not meet specifications, check the following items for possible malfunction:
a. Wiring and connections between gauge sending unit and multiple connector behind left kick
panel. b. Wiring and connections between multiple connector and printed circuit board terminals. c.
Circuit continuity between printed circuit board terminals and gauge terminals. If the above items
are satisfactory, the gauge is defective
and must be replaced.
6. If fuel gauge meets specifications check original fuel tank sending unit as follows:
a. Remove fuel tank sending unit from fuel tank and connect a jumper wire between sending unit
pick up tube and ground.
7. Repeat step 4. 8. If fuel gauge is now within specifications, check the following as possible
cause:
a. Ground wire from sending unit to left side cowl for continuity. b. Sending unit deformed. Ensure
float arm moves freely and pick up tube is not bent. c. Inspect float. d. Sending unit improperly
installed. Install correctly. e. Mounting flange on fuel tank for sending unit deformed. f.
Fuel tank bottom deformed causing improper positioning of pick-up tube.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Component Information > Locations
Fuel Tank Pressure Release Valve: Locations
Pressure Relief/Roll Over Valve
The Pressure Relief/Roll Over Valve is located on top of the fuel tank and may only be accessed
when the fuel tank has been lowered.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Component Information > Locations > Page 2673
Fuel Tank Pressure Release Valve: Service and Repair
Pressure Relief/Roll Over Valve
REMOVAL
1. Fuel system pressure must be released prior to service.
2. Fuel tank must be removed from vehicle prior to service. Refer to FUEL TANK REPLACEMENT
AND REPAIR PROCEDURES.
3. Slide the blade of a screwdriver between the rubber mounting grommet and the fuel tank,
making sure not to slide the screwdriver between the roll-over valve and grommet. Use a second
screwdriver to brace the first and pry the roll-over valve out of the tank.
4. Remove the grommet from the valve, and make sure there is no damage or wear evident on the
grommet. If grommet is worn it must be replaced.
Pressure Relief/Rollover Valve
INSTALLATION
1. Install the rubber grommet into the fuel tank, and seat it around the curled lip of the tank.
2. Lubricate the grommet with power steering fluid, and push roll-over valve into grommet until
properly seated. Twist grommet if necessary to align to correct position. Reinstall fuel tank.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations
Idle Speed/Throttle Actuator - Electronic: Component Locations
LH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 2678
Engine Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2679
Idle Speed/Throttle Actuator - Electronic: Description and Operation
The AIS motor is operated by the SMEC and controls engine idle speed by controlling air flow
through the throttle body by-pass channel. The SMEC computes proper idle speed based in signals
from vehicle and engine sensors and the switch inputs, and transmits voltage signals to the AIS
motor to open or close the by-pass channel in order to maintain the proper engine speed. Basic,
no-load idle speed is determined by the amount of air flowing through the throttle body past the
closed throttle plate. The AIS motor alters idle speed by allowing increased air flow through the
by-pass channel; increasing idle speed when the channel is opened and decreasing idle speed
when the channel is closed. In addition, the AIS motor is signaled to open the by-pass channel
during deceleration to prevent stalling and mixture enrichment caused by sudden closing of the
throttle plate.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2680
Idle Speed/Throttle Actuator - Electronic: Service and Repair
1. Disconnect battery ground cable, then remove air cleaner assembly.
2. Disconnect four pin connector from AIS, then remove temperature sending unit from throttle
body housing.
3. Remove two AIS to throttle body torx head retaining screws.
4. Remove AIS from throttle body housing with O-ring.
5. Reverse procedure to install. Install new O-ring and torque retaining screws to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Component Locations
Main Relay (Computer/Fuel System): Component Locations
Relay Locations--next To Battery
The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the
inner fender.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Component Locations > Page 2685
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Diagrams > Diagram Information and Instructions
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Diagrams > Diagram Information and Instructions > Page 2688
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Diagrams > Page 2689
Main Relay (Computer/Fuel System): Description and Operation
Relay Locations--next To Battery
The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel
pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel
injectors, and electric fuel pump at all times when the ignition switch is in the START position.
When the ignition switch is in the RUN position and the engine control module is receiving
reference signals from the distributor, power will also be supplied. If there is no reference signal
after two seconds the engine control module will de-energize the ASD and no power will be
supplied to the ignition coil, fuel injectors, or electric fuel pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay
Relay Terminal Identification
ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with
circuit codes, and color codes, and their function:
Circuit No. Terminal No. Color Code Description
J1 30 Red Has battery input voltage supplied through fusible link.
Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output
voltage to fuel pump, O2 sensor, fuel injectors, and coil.
K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine
Controller (SMEC). The SMEC provides input voltage to relay.
K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when
distributor signal is present.
N/A 87A N/A Not used in these applications.
ASD RELAY TEST
NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent.
Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no
scanner is available proceed with the following test.
1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage.
If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present
proceed to step 2.
2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to
the START position and crank the engine. If
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2692
output voltage is present during cranking, the ASD relay is functioning normally and no further
testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3.
3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key
to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is
present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC
connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86)
wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If
continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for
SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD
relay, and test operation.
4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START
position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and
drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning,
and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If
no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14
(terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists
replace and ASD relay and test operation.
5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter
between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58
of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and
ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE
CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Engine Compartment Components
This vehicle utilizes the Automatic Shutdown (ASD) Relay to control the Fuel Pump operation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component
Locations
Main Relay (Computer/Fuel System): Component Locations
Relay Locations--next To Battery
The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the
inner fender.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component
Locations > Page 2701
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram
Information and Instructions
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram
Information and Instructions > Page 2704
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 2705
Main Relay (Computer/Fuel System): Description and Operation
Relay Locations--next To Battery
The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel
pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel
injectors, and electric fuel pump at all times when the ignition switch is in the START position.
When the ignition switch is in the RUN position and the engine control module is receiving
reference signals from the distributor, power will also be supplied. If there is no reference signal
after two seconds the engine control module will de-energize the ASD and no power will be
supplied to the ignition coil, fuel injectors, or electric fuel pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto
Shutdown (ASD) Relay
Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay
Relay Terminal Identification
ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with
circuit codes, and color codes, and their function:
Circuit No. Terminal No. Color Code Description
J1 30 Red Has battery input voltage supplied through fusible link.
Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output
voltage to fuel pump, O2 sensor, fuel injectors, and coil.
K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine
Controller (SMEC). The SMEC provides input voltage to relay.
K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when
distributor signal is present.
N/A 87A N/A Not used in these applications.
ASD RELAY TEST
NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent.
Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no
scanner is available proceed with the following test.
1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage.
If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present
proceed to step 2.
2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to
the START position and crank the engine. If
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto
Shutdown (ASD) Relay > Page 2708
output voltage is present during cranking, the ASD relay is functioning normally and no further
testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3.
3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key
to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is
present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC
connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86)
wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If
continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for
SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD
relay, and test operation.
4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START
position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and
drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning,
and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If
no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14
(terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists
replace and ASD relay and test operation.
5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter
between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58
of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and
ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE
CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Component Information > Locations
Rollover Valve: Locations
Pressure Relief/Roll Over Valve
The Pressure Relief/Roll Over Valve is located on top of the fuel tank and may only be accessed
when the fuel tank has been lowered.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Component Information > Locations > Page 2712
Rollover Valve: Service and Repair
Pressure Relief/Roll Over Valve
REMOVAL
1. Fuel system pressure must be released prior to service.
2. Fuel tank must be removed from vehicle prior to service. Refer to FUEL TANK REPLACEMENT
AND REPAIR PROCEDURES.
3. Slide the blade of a screwdriver between the rubber mounting grommet and the fuel tank,
making sure not to slide the screwdriver between the roll-over valve and grommet. Use a second
screwdriver to brace the first and pry the roll-over valve out of the tank.
4. Remove the grommet from the valve, and make sure there is no damage or wear evident on the
grommet. If grommet is worn it must be replaced.
Pressure Relief/Rollover Valve
INSTALLATION
1. Install the rubber grommet into the fuel tank, and seat it around the curled lip of the tank.
2. Lubricate the grommet with power steering fluid, and push roll-over valve into grommet until
properly seated. Twist grommet if necessary to align to correct position. Reinstall fuel tank.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel
Injection - TPS Diagnostic Procedure Revision
Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure
Revision
Models
1989 AS
Subject
Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI
Index
MISCELLANEOUS
Date
December 29, 1989
No.
26-34-89 P-13 (C26-34-9) BODY CODE LEGEND
AS - 1989 RAM VAN, CARAVAN, VOYAGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel
Injection - TPS Diagnostic Procedure Revision > Page 2718
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel
Injection - TPS Diagnostic Procedure Revision > Page 2719
DIAGNOSTIC MANUAL REVISION
Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This
revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH.
1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No.
81-699-9017. Pages 136 and 137.
Please affix these revised pages in your manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2720
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2721
Throttle Position Sensor: Locations
LH Rear Corner Of Cylinder Head
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Throttle Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2724
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2725
Throttle Position Sensor: Description and Operation
The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The
sensor produces a voltage signal which increases and decreases according to throttle position. The
SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide
open throttle, acceleration and deceleration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2726
Throttle Position Sensor: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle
body mounting screws.
3. Lift TPS from throttle shaft, then remove O-ring.
4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw
to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 180889 > May > 89 > Throttle Body Intermittent Loss of Engine Power
Throttle Body: Customer Interest Throttle Body - Intermittent Loss of Engine Power
Models
1987-89 S/AS & C/AC Bodies 1989 AA Body All With 3.0L Engine
Subject
Intermittent Loss Of Engine Power During Slow Speed Deceleration
Index
DRIVEABILITY
Date May 30, 1989
No.
18-08-89
(C18-09-9)
P-2096 BODY CODE LEGEND
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V AA SPIRIT/ACCLAIM
SYMPTOM/CONDITION
Intermittent loss of power (3.0L engine) during slow speed deceleration.
PARTS REQUIRED
1 Mopar Parts Cleaner PN 4318037
1 Throttle Body Base Gasket PN 4300071
(1987-88)
1 Throttle Body Base Gasket PN 4324426
(1989)
Scotch Brite Pad (Green)
REPAIR PROCEDURE
If the engine idles slow or rough after deceleration, or requires long crank times when cold, it may
be caused by residue which has accumulated between the throttle blade and the throttle body bore.
This residue will restrict airflow at closed throttle. Removing this residue from the throttle body bore
and throttle blade should return the minimum air flow speed to proper specifications.
1. Perform the minimum airflow test as outlined in the Powertrain Diagnostics Procedures Manual.
Be sure to use Miller Tool C-5004 when checking minimum air flow RPM.
2. If the minimum airflow RPM is below 800 RPM as indicated on the DRB II, remove the throttle
body from the engine.
3. While holding the throttle open, spray the throttle body bore with Mopar Parts Cleaner PN
4318037. Spray the entire throttle body bore and the manifold side of the throttle blade. It is
important to use only Mopar Parts Cleaner PN 4318037. Do not submerse the throttle body in
solvents, gasoline or any other cleaning fluids.
CAUTION: USE THIS CLEANER ONLY IN A WELL VENTILATED AREA. DO NOT LET THIS
CLEANER COME IN CONTACT WITH SKIN. RUBBER OR BUTYL GLOVES ARE
RECOMMENDED. WASH THOROUGHLY AFTER USE. AVOID EYE CONTACT. AVOID
INGESTING.
4. Use a small (1" x 1") piece of green Scotch Brite scuff pad to clean the throttle body bore and the
throttle blade. While holding the throttle open, clean both the top and bottom of the throttle body
bore. Also clean the manifold side and edges of the throttle blade-.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 180889 > May > 89 > Throttle Body Intermittent Loss of Engine Power > Page 2735
NOTE: IT IS IMPORTANT THIS CLEANING OPERATION BE PERFORMED THOROUGHLY AND
COMPLETELY. THE EDGE OF THE THROTTLE BLADE AND THE PORTION OP THE
THROTTLE BODY BORE THAT IS IN THE CLOSEST PROXIMITY OF THE CLOSED THROTTLE
BLADE ARE THE MOST CRITICAL AREAS THE CLEANING SHOULD BE CONCENTRARED.
THESE AREAS MUST BE FREE OF ALL DEPOSITS WHEN THE CLEANING IS COMPLETED.
5. Spray the throttle body with Mopar Parts Cleaner PN 4318037 and then blow dry with
compressed shop air. Inspect for any foreign material which may have been left behind from the
cleaning process.
CAUTION: DO NOT APPLY SHOP AIR PRESSURE DIRECTLY INTO THROTTLE SHAFT AND
THROTTLE BODY HOUSING HOLES.
6. Reinstall the throttle body and check to see if the minimum air flow RPM is within specification. If
the air flow is still not within specification, repeat the cleaning procedure in step 4 above. If the
minimum air flow RPM is still not within specification, the problem is not caused by throttle body
contamination.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 14-30-01-99
. . . . . . . . . . . . . . . . 1.2 Hrs.
FAILURE CODE: 08 - Blocked
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 180889 > May > 89 > Throttle
Body - Intermittent Loss of Engine Power
Throttle Body: All Technical Service Bulletins Throttle Body - Intermittent Loss of Engine Power
Models
1987-89 S/AS & C/AC Bodies 1989 AA Body All With 3.0L Engine
Subject
Intermittent Loss Of Engine Power During Slow Speed Deceleration
Index
DRIVEABILITY
Date May 30, 1989
No.
18-08-89
(C18-09-9)
P-2096 BODY CODE LEGEND
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V AA SPIRIT/ACCLAIM
SYMPTOM/CONDITION
Intermittent loss of power (3.0L engine) during slow speed deceleration.
PARTS REQUIRED
1 Mopar Parts Cleaner PN 4318037
1 Throttle Body Base Gasket PN 4300071
(1987-88)
1 Throttle Body Base Gasket PN 4324426
(1989)
Scotch Brite Pad (Green)
REPAIR PROCEDURE
If the engine idles slow or rough after deceleration, or requires long crank times when cold, it may
be caused by residue which has accumulated between the throttle blade and the throttle body bore.
This residue will restrict airflow at closed throttle. Removing this residue from the throttle body bore
and throttle blade should return the minimum air flow speed to proper specifications.
1. Perform the minimum airflow test as outlined in the Powertrain Diagnostics Procedures Manual.
Be sure to use Miller Tool C-5004 when checking minimum air flow RPM.
2. If the minimum airflow RPM is below 800 RPM as indicated on the DRB II, remove the throttle
body from the engine.
3. While holding the throttle open, spray the throttle body bore with Mopar Parts Cleaner PN
4318037. Spray the entire throttle body bore and the manifold side of the throttle blade. It is
important to use only Mopar Parts Cleaner PN 4318037. Do not submerse the throttle body in
solvents, gasoline or any other cleaning fluids.
CAUTION: USE THIS CLEANER ONLY IN A WELL VENTILATED AREA. DO NOT LET THIS
CLEANER COME IN CONTACT WITH SKIN. RUBBER OR BUTYL GLOVES ARE
RECOMMENDED. WASH THOROUGHLY AFTER USE. AVOID EYE CONTACT. AVOID
INGESTING.
4. Use a small (1" x 1") piece of green Scotch Brite scuff pad to clean the throttle body bore and the
throttle blade. While holding the throttle open, clean both the top and bottom of the throttle body
bore. Also clean the manifold side and edges of the throttle blade-.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 180889 > May > 89 > Throttle
Body - Intermittent Loss of Engine Power > Page 2741
NOTE: IT IS IMPORTANT THIS CLEANING OPERATION BE PERFORMED THOROUGHLY AND
COMPLETELY. THE EDGE OF THE THROTTLE BLADE AND THE PORTION OP THE
THROTTLE BODY BORE THAT IS IN THE CLOSEST PROXIMITY OF THE CLOSED THROTTLE
BLADE ARE THE MOST CRITICAL AREAS THE CLEANING SHOULD BE CONCENTRARED.
THESE AREAS MUST BE FREE OF ALL DEPOSITS WHEN THE CLEANING IS COMPLETED.
5. Spray the throttle body with Mopar Parts Cleaner PN 4318037 and then blow dry with
compressed shop air. Inspect for any foreign material which may have been left behind from the
cleaning process.
CAUTION: DO NOT APPLY SHOP AIR PRESSURE DIRECTLY INTO THROTTLE SHAFT AND
THROTTLE BODY HOUSING HOLES.
6. Reinstall the throttle body and check to see if the minimum air flow RPM is within specification. If
the air flow is still not within specification, repeat the cleaning procedure in step 4 above. If the
minimum air flow RPM is still not within specification, the problem is not caused by throttle body
contamination.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 14-30-01-99
. . . . . . . . . . . . . . . . 1.2 Hrs.
FAILURE CODE: 08 - Blocked
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > Page 2742
Throttle Body: Locations
Throttle Body
The Throttle Body Assembly is mounted to the end of the intake plenum, on the left (drivers) side. It
has a hose mounted to it connecting the air cleaner to the throttle body.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > Page 2743
Throttle Body: Description and Operation
Fig. 6 Throttle body assembly
The throttle body, Fig. 6, assembly is located on the left end of the air intake plenum and houses
the throttle plate, throttle position sensor and the AIS motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > Page 2744
Throttle Body: Testing and Inspection
1. Remove air cleaner assembly, then plug heated air door vacuum hose.
2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan
cycles ON and OFF at least once. STOP engine.
3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and
ensure basic timing is set to 12° BTDC.
4. STOP engine and reconnect coolant temperature sensor wire.
5. Disconnect PCV valve hose from intake manifold nipple.
6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV
nipple.
7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1
minute.
8. Using scanner, place read/hold switch in read position and depress ATM button until code 70
appears.
9. Place read/hold switch to hold position, then the following should occur: a.
AIS motor will fully close.
b. Idle spark advance will become fixed.
c. Idle fuel will become enriched.
d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example,
display 95 equals 95 x 10 which indicates 950 rpm.
10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is
satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE
PROCEDURES. Retest minimum air flow after throttle body cleaning.
11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install
PCV valve hose.
12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door
vacuum hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Throttle Body Cleaning
Throttle Body: Service and Repair Throttle Body Cleaning
1. Under normal or severe operating conditions, it is possible for the throttle body to build deposits
in the air flow area near the PCV inlet, and/or near the Automatic Idle Speed (AIS) inlet. These
deposits can cause driveability problems that may or may not appear as a fault code in diagnosis.
2. Visually inspect the throttle body air flow area and if deposits are present refer to Powertrain
Management/Fuel Delivery and Air Induction /Throttle Body/Service and Repair and remove the
throttle body. Carefully clean any deposits from the throttle body air flow area, and insure that the
intake plenum is also clean. NOTE: Do not use harsh abrasives or tank solvent washing to clean
the throttle body.
3. Reinstall the throttle body and intake plenum if it was removed, refer to Powertrain
Management/Fuel Delivery and Air Induction/Testing and Inspection/Procedures, and perform the
test. If the throttle body fails the minimum air flow test no further service is possible and the throttle
body must be replaced.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Throttle Body Cleaning > Page 2747
Throttle Body: Service and Repair Throttle Body Replacement
Throttle Body
REMOVAL
1. Disconnect negative battery terminal, and remove air cleaner hose and clamp. Disconnect and
remove throttle cable, and transaxle linkage.
2. Disconnect Automatic Idle Speed (AIS) motor, and Throttle Position Sensor (TPS). Disconnect
vacuum hoses from throttle body.
3. Remove throttle body to intake manifold mounting nuts. Remove throttle body and gasket.
INSTALLATION
1. Install throttle body with new gasket and torque mounting nuts to 20 Nm (175 lb-in).
2. Install throttle body vacuum hoses, TPS connector, and AIS motor connector. Install throttle
cable.
3. Install air cleaner hose and clamp and torque clamp to 3 Nm (30 lb-in). Connect negative battery
terminal and check operation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Service and Repair
Throttle Cable/Linkage: Service and Repair
Accelerator Pedal Assembly
REMOVAL
1. Inside vehicle hold up the gas pedal and remove the throttle cable retainer and throttle cable
from the upper end of the pedal shaft. The throttle lever must be rotated towards wide open throttle
to allow enough cable slack to permit removal.
2. From the engine compartment pull the throttle cable out through the dash, leaving the dash
grommet in place.
Throttle Cable
3. Remove the throttle cable from the throttle lever, then remove cable from throttle bracket.
INSTALLATION
1. Install the cable housing into the cable mounting bracket on the engine. Install cable end into
second groove of the throttle cam. Push cable through dash grommet and reconnect to accelerator
pedal.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision
Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure
Revision
Models
1989 AS
Subject
Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI
Index
MISCELLANEOUS
Date
December 29, 1989
No.
26-34-89 P-13 (C26-34-9) BODY CODE LEGEND
AS - 1989 RAM VAN, CARAVAN, VOYAGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2755
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2756
DIAGNOSTIC MANUAL REVISION
Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This
revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH.
1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No.
81-699-9017. Pages 136 and 137.
Please affix these revised pages in your manual.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 2757
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 2758
Throttle Position Sensor: Locations
LH Rear Corner Of Cylinder Head
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2761
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Page 2762
Throttle Position Sensor: Description and Operation
The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The
sensor produces a voltage signal which increases and decreases according to throttle position. The
SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide
open throttle, acceleration and deceleration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Page 2763
Throttle Position Sensor: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle
body mounting screws.
3. Lift TPS from throttle shaft, then remove O-ring.
4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw
to 20 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications > Cylinder Location
1988-1996 3.0L (182)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications > Cylinder Location > Page 2769
Distributor Cap From The Top - Includes Connections Inside The Cap. (Round Terminals Are Plug
Wire Connections On The Top Of The Cap.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Number One Cylinder: Locations
1988-1996 3.0L (182)
3.0L Except Stealth
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators >
System Information > Diagrams
Timing Marks and Indicators: Diagrams
TIMING MARK 3.0L
Timing Scale Above Crank Pulley--Viewed From Front Of Car
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 2781
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Senior 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 2787
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Page 2788
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information >
Specifications
Distributor: Specifications
Distributer Adapter ...............................................................................................................................
.......................................... 14 Nm (120 in lbs) Distributer Housing Bolt .............................................
.................................................................................................................... 15 Nm (130 in lbs)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information >
Specifications > Page 2792
Distributor: Locations
Distributor Hold-Down
The Optical Distributor is located at the back of the engine, behind the right-hand cylinder head.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information >
Specifications > Page 2793
Distributor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications
Ignition Cable: Specifications
Minimum
..................................................................................................................................................... 250
ohms per inch (3,000 ohms per foot)
Maximum
............................................................................................................................................... 1,000
ohms per inch (12,000 ohms per foot)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 2800
Ignition Coil: Description and Operation
The Ignition Coil is designed to step up primary voltage of 12V to 25,000-35,000V. It is composed
of a primary winding, secondary winding and a core of soft iron. The primary winding is made up of
approximately 200 turns of heavy wire (approximately No. 18 gauge). The secondary winding is
wound around the soft iron core, and the primary wiring surrounds the secondary. The purpose of
the core is to concentrate the magnetic field. It transforms the battery voltage to the high secondary
voltage (about 28kv) every time it receives a signal.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information
> Diagrams > Diagram Information and Instructions
Ignition Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information
> Diagrams > Diagram Information and Instructions > Page 2805
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Ignition Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2811
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2817
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Senior 105 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2823
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Page 2824
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect distributor lead wire at wiring harness connector.
2. Remove distributor cap retaining screws and remove distributor cap.
3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum.
Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when
reinstalling the distributor.
4. Remove the distributor hold down nut and remove the distributor from the engine.
DISASSEMBLY
1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and
remove lead wire.
2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or
damaged slots.
3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing.
4. Remove 2 bearing retainer screws.
5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the
distributor drive gear roll pin.
6. Remove distributor drive gear, remove distributor shaft and bearing assembly.
REASSEMBLY
1. Install shaft and bearing assembly in distributor housing.
2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference
marks made during disassembly, and install roll pin.
3. Install distributor shaft bearing retaining screws.
4. Install the photo optic sensing unit and bushing and tighten with 3 screws.
5. Install disk spacers and disk. Install disk assembly screw.
6. Install lead wire, and lead wire clamp screw.
7. Install protective cover on distributor housing.
INSTALLATION
1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If
engine has been cranked with distributor removed proceed to step 3 for installation.
2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is
not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the
distributor is installed, the rotor will be in line with the previously scribed line on the air intake
plenum. Proceed to step 4.
3. If the engine has been cranked with the distributor removed perform the following procedure: a.
Rotate the crankshaft until the number one piston is at the top of its compression stroke.
Distributor Cap Terminal Routing
b. Rotate the distributor shaft until the rotor points to number one terminal.
c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam
shaft. With the distributor fully seated the rotor should be under the number one terminal.
4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers.
Install hold down nut finger tight.
5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to
ADJUSTMENT PROCEDURES for timing adjustment.
.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Component Information > Locations
Ignition Switch: Locations
I/P, Cowl & Steering Column Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Component Information > Locations > Page 2828
Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Component Information > Locations > Page 2829
Ignition Switch: Service and Repair
Fig. 10 Ignition switch replacement
1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES.
2. Remove left lower instrument panel cover.
3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle.
4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts.
5. Lower column and disconnect ignition switch electrical connector.
6. Position ignition lock cylinder in Lock position.
7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder
assembly.
8. Remove two ignition switch attaching screws, then the switch.
9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap Specifications
Spark Plug: Specifications Gap Specifications
Refer to the Vehicle Emission Control Information (VECI) label, (under hood).
If label is gone, or not readable, verify system and use the following specification.
Plug Gap ..............................................................................................................................................
.................... 0.9 to 1.1 mm (0.039 to 0.044 in)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap Specifications > Page 2834
Spark Plug: Specifications Tightening Specifications
Spark Plug Torque ...............................................................................................................................
...................................................... 28 Nm (20 ft. lbs.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To
Stop
Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To
Stop > Page 2846
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When
Coming To Stop
Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When
Coming To Stop > Page 2852
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > Page 2853
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > Page 2854
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 >
Converter Lock Up Solenoid - Bucking/Surging
Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 >
Converter Lock Up Solenoid - Bucking/Surging > Page 2863
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 >
Converter Lock Up Solenoid - Bucking/Surging > Page 2864
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 >
Converter Lock Up Solenoid - Bucking/Surging > Page 2865
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290
> Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging
Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290
> Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2871
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290
> Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2872
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290
> Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2873
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Component Locations
Torque Converter Clutch Solenoid: Component Locations
Part Throttle Unlock Solenoid (3speed)
LH Side Of Engine Compartment 3 Speed Automatic
RH Side Of Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Component Locations > Page 2876
Applicable to: 3 Speed A-413 Automatic Transaxle
4 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Component Locations > Page 2877
Electrical Connections, 3 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Page 2878
Torque Converter Clutch Solenoid: Description and Operation
Part Throttle Unlock Solenoid (3 Speed Automatic)
This solenoid is controlled by the engine controller. The engine controller applies and removes the
ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque
converter is only locked up when the transmission is in direct drive and when the throttle position is
not fluctuating. If the engine controller receives a signal from the throttle position sensor that an
increase or decrease in throttle is needed (when the transmission gear selector is in direct drive),
the engine controller will disengage the part throttle solenoid causing the lock-up torque converter
to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2889
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2890
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2891
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2892
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2893
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2894
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 2899
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 2904
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting
Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 2909
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 2915
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 2916
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 2917
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 2918
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 2919
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 2920
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st
Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st
Gear Downshift > Page 2925
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear
Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear
Downshift > Page 2930
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive
Upshifting/Downshifting
Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive
Upshifting/Downshifting > Page 2935
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2940
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2941
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2942
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2948
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2949
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2950
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module > Page 2953
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2954
Control Module: Diagrams
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2955
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2956
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2957
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2958
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2959
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2960
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2961
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2962
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2963
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 2964
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > A604
Control Module: Description and Operation A604
DESCRIPTION
This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped
similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code
memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > A604 > Page 2967
Control Module: Description and Operation 41TE
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > A604 > Page 2968
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > General Information > Page 2971
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations
Transmission Control System Relay: Locations
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 2975
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 2976
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 2977
Transmission Control System Relay: Description and Operation
DESCRIPTION
This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to
the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay,
voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in
this mode, only second gear, reverse and neutral are available.
This relay may also be referred to as the Safety Shutdown Relay.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information >
Locations > Component Locations
Transmission Position Relay: Component Locations
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information >
Locations > Component Locations > Page 2982
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation
Transmission Mode Switch: Description and Operation
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the
transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 2996
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 2997
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 2998
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3004
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3005
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3010
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3011
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3012
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change > Page 3018
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change > Page 3019
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3022
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3023
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3024
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > PRNDL Switch > Page 3027
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Description and Operation > Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Description and Operation > Transmission Range Sensor > Page 3030
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > Sensor, Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > Sensor, Transmission Range > Page 3033
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > Sensor, Transmission Range > Page 3034
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > Sensor, Transmission Range > Page 3035
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 3044
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 3049
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 3050
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 3051
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control > Page 3057
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3062
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3063
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3064
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 3065
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Description and Operation > Output Speed Sensor
Transmission Speed Sensor: Description and Operation Output Speed Sensor
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Description and Operation > Output Speed Sensor > Page 3068
Transmission Speed Sensor: Description and Operation Turbine Speed Sensor
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque
convertor turbine).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Description and Operation > Page 3069
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation
Transmission Temperature Sensor/Switch: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop
Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3084
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop
Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3090
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3091
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3092
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service
Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging
Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service
Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3101
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service
Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3102
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service
Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3103
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up
Solenoid - Bucking/Surging
Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up
Solenoid - Bucking/Surging > Page 3109
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up
Solenoid - Bucking/Surging > Page 3110
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up
Solenoid - Bucking/Surging > Page 3111
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations >
Component Locations
Torque Converter Clutch Solenoid: Component Locations
Part Throttle Unlock Solenoid (3speed)
LH Side Of Engine Compartment 3 Speed Automatic
RH Side Of Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations >
Component Locations > Page 3114
Applicable to: 3 Speed A-413 Automatic Transaxle
4 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations >
Component Locations > Page 3115
Electrical Connections, 3 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3116
Torque Converter Clutch Solenoid: Description and Operation
Part Throttle Unlock Solenoid (3 Speed Automatic)
This solenoid is controlled by the engine controller. The engine controller applies and removes the
ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque
converter is only locked up when the transmission is in direct drive and when the throttle position is
not fluctuating. If the engine controller receives a signal from the throttle position sensor that an
increase or decrease in throttle is needed (when the transmission gear selector is in direct drive),
the engine controller will disengage the part throttle solenoid causing the lock-up torque converter
to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: >
211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop
Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: >
211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3127
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift
Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop
Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift
Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3133
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3134
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3135
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest
for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging
Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest
for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3144
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest
for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3145
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest
for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3146
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging
Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3152
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3153
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3154
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations
Torque Converter Clutch Solenoid: Component Locations
Part Throttle Unlock Solenoid (3speed)
LH Side Of Engine Compartment 3 Speed Automatic
RH Side Of Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3157
Applicable to: 3 Speed A-413 Automatic Transaxle
4 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3158
Electrical Connections, 3 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3159
Torque Converter Clutch Solenoid: Description and Operation
Part Throttle Unlock Solenoid (3 Speed Automatic)
This solenoid is controlled by the engine controller. The engine controller applies and removes the
ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque
converter is only locked up when the transmission is in direct drive and when the throttle position is
not fluctuating. If the engine controller receives a signal from the throttle position sensor that an
increase or decrease in throttle is needed (when the transmission gear selector is in direct drive),
the engine controller will disengage the part throttle solenoid causing the lock-up torque converter
to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Specifications > Kickdown
Band: Specifications
Kickdown Band Adjustment Locknut 35 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Specifications > Kickdown > Page 3164
Band: Specifications
Raverse Band Adjusting Locknut 120 in.lb
Reverse Band Shaft Plug 60 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Adjustments > Front Band Adjustment
Band: Adjustments Front Band Adjustment
Fig. 4 Kickdown band adjusting screw location
1. Loosen locknut and back off nut approximately 5 turns, Fig. 4. Ensure adjusting screw turns
freely in transaxle case.
2. Using adjusting screw tightener tool No. C-3380-A and C-3705, torque band adjusting screw to
47-50 inch lbs. If tightener tool No. C-3705 is not used, torque adjusting screw to 72 inch lbs.
3. Back off adjusting screw 2-1/2 turns.
4. Hold adjusting screw in this position and torque locknut to 35 ft-lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Adjustments > Front Band Adjustment > Page 3167
Band: Adjustments Rear Band Adjustment
1. Loosen, then back off locknut approximately 5 turns.
2. Torque adjusting screw to 41 inch lbs.
3. Back off adjusting screw 3-1/2 turns and torque locknut to 10 ft-lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T
- Slips In Reverse At Low Temperature
Band Apply Servo: Customer Interest A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T
- Slips In Reverse At Low Temperature > Page 3176
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T
- Slips In Reverse At Low Temperature > Page 3177
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T
- Slips In Reverse At Low Temperature > Page 3178
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 >
Apr > 96 > A/T - Slips In Reverse At Low Temperature
Band Apply Servo: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 >
Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3184
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 >
Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3185
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 >
Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3186
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 212290 > Nov > 90 > A/T - A604 1-2 Gear Upshift Shudder
Clutch: Customer Interest A/T - A604 1-2 Gear Upshift Shudder
SUBJECT: 1-2 Upshift Shudder 1989-91 Vehicles Equipped With A-604 Transmission NO.:
21-22-90
GROUP: TRANSMISSION
DATE: Nov. 19, 1990
MODELS:
1989-91 (AA) SPIRIT/ACCLAIM/LEBARON
(AC) DYNASTY/NEW YORKER/LANDAU/SALON
(AG) DAYTONA
(AJ) LEBARON COUPE/LEBARON CONVERTIBLE
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION:
Some vehicles equipped with the A-604 transmission may exhibit an occasional shudder during the
1-2 upshift. This condition is most noticeable when the vehicle is being operated on a smooth
blacktop road after the transmission has reached normal operating temperature.
DIAGNOSIS:
Check transmission fluid level and condition. Connect the DRB II. Record fault codes. Perform the
diagnostic test as outlined in the appropriate Powertrain Diagnostic Manual. Be sure to complete
the shift lever test, clutch test and record clutch volumes (CVI).
Select the RPM display on the DRB II. Road test the vehicle a sufficient distance to ensure the
transmission has warmed up.
NOTE: THE FOLLOWING STEP SHOUID BE PERFORMED ON A SMOOTH BLACKTOP ROAD.
Initiate a 1-2 upshift from a throttle angle (TSP) of 10" through wide open throttle in steps of 50.
If shudder was experienced during the 1-2 upshift, perform the repair procedure.
If no shudder was experienced, but fluid condition, fault codes, shift lever test or clutch test indicate
a problem, correct as required.
PARTS REQUIRED: REPAIR PROCEDURE:
This repair involves removing the transaxle, and reconditioning the 2-4 clutch.
Use the appropriate Service Manual as a guide in performing the following steps.
1. Remove the transaxle assembly.
2. Remove the oil pan and valve body.
3. Measure and record the input shaft end play.
4. Remove input speed sensor.
5. Remove the oil pump and gasket.
NOTE: ON 1991 VEHICLES BE SURE TO REMOVE THE INTERNAL OIL COOLER BYPASS
VALVE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 212290 > Nov > 90 > A/T - A604 1-2 Gear Upshift Shudder
> Page 3195
6. Remove the No. 1 caged needle bearing.
7. Remove the input clutch assembly.
8. Remove the front sun gear and No. 4 thrust washer.
9. Remove the front carrier and rear annulus assembly and the No. 6 needle bearing.
10. Remove the rear sun gear and No. 7 needle bearing.
11. Remove the 2-4 clutch retainer snap ring using tool 5058.
12. Remove the 2-4 clutch retainer and return spring.
13. Disassemble and clean the 2-4 clutch retainer and piston.
14. Install the 4 new clutch discs PN 4567212, and 4 new clutch plates PN 4412247.
15. Assemble the 2-4 retainer, using new clutch seal package PN 4504050.
16. Install the 2-4 retainer, spring, and snap ring.
17. Check the 2-4 clutch clearance. The clearance should be 0.76 to 2.64 mm (.030 to .140). If
clearance is not within specification, the clutch is not assembled properly.
18. Install the rear sun gear and No. 7 needle bearing.
19. Install the front carrier and rear annulus assembly and the No. 6 needle bearing.
20. Install the front sun gear and No. 4 thrust washer.
NOTE: IF INPUT SHAFT END PLAY WAS FOUND OUT OF SPECIFICATION .13 TO .64 mm
(.005 To .025) DURING DISASSEMBLY REPIACE THE NO. 4 THRUST WASHER WITH THE
CORRECT WASHER AT THIS TIME.
21. Install the input clutch assembly.
22. Install the No. 1 caged needle bearing.
23. Install oil pump using new gasket package PN 4504555.
NOTE: ON 1991 VEHICLES BE SURE TO INSTALL THE INTERNAL OIL COOLER BYPASS
VALVE.
24. Install input speed sensor.
25. Check input shaft end play.
26. Install the valve body, using new valve body gasket package PN 4504553.
27. Install oil pan.
28. Install the transaxle assembly.
29. Refill the transaxle with MOPAR ATF PLUS (ATF Type 7176), or DEXTRON II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
1-2 Upshift Shudder 21-34-02-92 ........ 4.8 Hrs.
FAILURE CODE: 58 - Internal defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210996 > Jun > 96 > A/T - Clutch
Volume Index QuIck Learn
Clutch: All Technical Service Bulletins A/T - Clutch Volume Index QuIck Learn
NO: 21-09-96
GROUP: Transmission
DATE: June 28, 1996
SUBJECT: Clutch Volume Index Quick Learn Procedure Requirement After Transaxle Overhaul Or
Replacement-41TE Transaxle
MODELS:
1989 - 1992 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1992 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1992 (AG) Daytona
1989 - 1992 (AJ) LeBaron Coupe/LeBaron Convertible
1992 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1992 (AS) Town & Country/Caravan/Voyager
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
DISCUSSION:
NOTE:
FAILURE TO PERFORM THE QUICK LEARN PROCEDURE OR BATTERY DISCONNECT, AS
DESCRIBED BELOW, AFTER A TRANSAXLE IS REPLACED OR OVERHAULED CAN RESULT
IN A LOW MILEAGE TRANSAXLE FAILURE OR POOR INITIAL SHIFT QUALITY.
The DRB III will now support the quick learn procedure for the 1989 thru 1992 Model Year Vehicles
equipped with a service replacement EATX II (with cooling fins) Transmission Control Module
(TCM) having the following part numbers:
4796121, 4796122, 4696123, 4696124.
For EATX II TCM part numbers that precede the above list, refer to Repair Procedure No. 1 of
Technical Service Bulletin 18-24-95, dated June 23, 1995.
NOTE:
1993 AND LATER 41TE/42LE TCM'S HAVE ALWAYS BEEN QUICK LEARN CAPABLE.
For EATX I (without cooling fins) TCM's, disconnecting the battery for one minute or performing the
battery disconnect function with the DRB will reset the clutch volume index (CVI) to an acceptable
range and the quick learn procedure is not required.
You must use DRB III code version 19.2 (released on Mar. 1, 1996 with TIL disc 1102) or later in
order to be able to quick learn 1989 thru 1992 model year vehicles. Quick learn must be done on
any 41TE or 42LE equipped vehicle when the transmission has been replaced or where
transmission work has been performed which affects CVI. For example, clutch pack replacements.
NOTE:
THE READING OF EATX DIAGNOSTIC TROUBLE CODES (DTC'S) AND PROPER
DIAGNOSTICS FOR 1989 THRU 1992 MODEL YEAR VEHICLES MUST BE PERFORMED
USING THE MDS AND A DRB II WITH THE APPROPRIATE CARTRIDGE OR DRB III, OR
USING A STAND ALONE DRB III WITH THE SUPER CARD INSTALLED.
AFTER PERFORMING DIAGNOSTICS YOU MUST ERASE ANY DTC'S USING ONE OF THE
TOOL CONFIGURATIONS LISTED ABOVE BEFORE PROCEEDING WITH THE QUICK LEARN
PROCEDURE.
PROCEDURE:
The EATX II quick learn procedure is required whenever a transaxle is repaired or replaced.
1. Ensure the transmission fluid level is correct.
2. Start vehicle, place the shift lever in Overdrive (OD), move the vehicle at least five feet with the
engine running and then place shifter in Neutral (N). Apply the parking brake and let the engine
idle. This purges the air in the clutch circuits to prevent erroneous clutch volume values which
could cause poor initial shift quality or a low mileage transaxle failure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210996 > Jun > 96 > A/T - Clutch
Volume Index QuIck Learn > Page 3201
3. Using the DRB III select the 1994 - 1997 Diagnostics option (1) and choose Transmissions.
4. Choose the Trans Overhauled/Replaced option and follow the instructions on the DRB III screen.
NOTE:
AFTER PERFORMING QUICK LEARN USE A PROPER DIAGNOSTIC CONFIGURATION TO
READ THE DTC'S. IF ONLY DTC 12 EXISTS, ERASE THE DTC. IF THERE ARE OTHER DTC'S,
PERFORM THE PROPER DIAGNOSTICS FOR THOSE DTC'S.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 212290 > Nov > 90 > A/T - A604 1-2
Gear Upshift Shudder
Clutch: All Technical Service Bulletins A/T - A604 1-2 Gear Upshift Shudder
SUBJECT: 1-2 Upshift Shudder 1989-91 Vehicles Equipped With A-604 Transmission NO.:
21-22-90
GROUP: TRANSMISSION
DATE: Nov. 19, 1990
MODELS:
1989-91 (AA) SPIRIT/ACCLAIM/LEBARON
(AC) DYNASTY/NEW YORKER/LANDAU/SALON
(AG) DAYTONA
(AJ) LEBARON COUPE/LEBARON CONVERTIBLE
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION:
Some vehicles equipped with the A-604 transmission may exhibit an occasional shudder during the
1-2 upshift. This condition is most noticeable when the vehicle is being operated on a smooth
blacktop road after the transmission has reached normal operating temperature.
DIAGNOSIS:
Check transmission fluid level and condition. Connect the DRB II. Record fault codes. Perform the
diagnostic test as outlined in the appropriate Powertrain Diagnostic Manual. Be sure to complete
the shift lever test, clutch test and record clutch volumes (CVI).
Select the RPM display on the DRB II. Road test the vehicle a sufficient distance to ensure the
transmission has warmed up.
NOTE: THE FOLLOWING STEP SHOUID BE PERFORMED ON A SMOOTH BLACKTOP ROAD.
Initiate a 1-2 upshift from a throttle angle (TSP) of 10" through wide open throttle in steps of 50.
If shudder was experienced during the 1-2 upshift, perform the repair procedure.
If no shudder was experienced, but fluid condition, fault codes, shift lever test or clutch test indicate
a problem, correct as required.
PARTS REQUIRED: REPAIR PROCEDURE:
This repair involves removing the transaxle, and reconditioning the 2-4 clutch.
Use the appropriate Service Manual as a guide in performing the following steps.
1. Remove the transaxle assembly.
2. Remove the oil pan and valve body.
3. Measure and record the input shaft end play.
4. Remove input speed sensor.
5. Remove the oil pump and gasket.
NOTE: ON 1991 VEHICLES BE SURE TO REMOVE THE INTERNAL OIL COOLER BYPASS
VALVE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 212290 > Nov > 90 > A/T - A604 1-2
Gear Upshift Shudder > Page 3206
6. Remove the No. 1 caged needle bearing.
7. Remove the input clutch assembly.
8. Remove the front sun gear and No. 4 thrust washer.
9. Remove the front carrier and rear annulus assembly and the No. 6 needle bearing.
10. Remove the rear sun gear and No. 7 needle bearing.
11. Remove the 2-4 clutch retainer snap ring using tool 5058.
12. Remove the 2-4 clutch retainer and return spring.
13. Disassemble and clean the 2-4 clutch retainer and piston.
14. Install the 4 new clutch discs PN 4567212, and 4 new clutch plates PN 4412247.
15. Assemble the 2-4 retainer, using new clutch seal package PN 4504050.
16. Install the 2-4 retainer, spring, and snap ring.
17. Check the 2-4 clutch clearance. The clearance should be 0.76 to 2.64 mm (.030 to .140). If
clearance is not within specification, the clutch is not assembled properly.
18. Install the rear sun gear and No. 7 needle bearing.
19. Install the front carrier and rear annulus assembly and the No. 6 needle bearing.
20. Install the front sun gear and No. 4 thrust washer.
NOTE: IF INPUT SHAFT END PLAY WAS FOUND OUT OF SPECIFICATION .13 TO .64 mm
(.005 To .025) DURING DISASSEMBLY REPIACE THE NO. 4 THRUST WASHER WITH THE
CORRECT WASHER AT THIS TIME.
21. Install the input clutch assembly.
22. Install the No. 1 caged needle bearing.
23. Install oil pump using new gasket package PN 4504555.
NOTE: ON 1991 VEHICLES BE SURE TO INSTALL THE INTERNAL OIL COOLER BYPASS
VALVE.
24. Install input speed sensor.
25. Check input shaft end play.
26. Install the valve body, using new valve body gasket package PN 4504553.
27. Install oil pan.
28. Install the transaxle assembly.
29. Refill the transaxle with MOPAR ATF PLUS (ATF Type 7176), or DEXTRON II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
1-2 Upshift Shudder 21-34-02-92 ........ 4.8 Hrs.
FAILURE CODE: 58 - Internal defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604
Momentary Decleration/Clutch Slippage
Technical Service Bulletin # 210189A Date: 890522
A/T - A604 Momentary Decleration/Clutch Slippage
Models
1989 AC & AS Bodies Equipped With A604 Transaxle
Subject
Momentary Deceleration, Default To Second Gear (Limp-In) Mode Or Excessive Clutch Slippage
During 3-4 Upshift
Index
TRANSMISSION
Date
May 22, 1989
No.
21-01-89 REVISION A
(21-19-9) P-1962 BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - CARAVAN/VOYAGER
THIS BULLETIN SERVICE TECHNICAL SERVICE BULLETIN # 21-01-89 (DATED 1/30/89)
WHICH SHOULD BE REMOVED FROM YOUR FILE.
NOTE: THIS TECHNICAL SERVICE BULLETIN IS ONLY TO BE USED IF CODES 39, 46 OR NO
CODES AT ALL ARE FOUND IN THE MEMORY.
SYMPTOM/CONDITION
- Momentary deceleration/loss of power during 3-4 shift.
- Default to 2nd gear after a 3-4 shift fault code 39: Gear
Ratio.
- Chronic inability in achieving 4th. gear.
- Excessive clutch slippage during a 3-4 shift.
These symptoms may result from an improperly functioning seal ring between the underdrive and
overdrive clutch circuits. During a 3-4 shift, fluid may leak into the underdrive circuit causing the
underdrive clutch to drag.
DIAGNOSIS
Use procedure on following pages for diagnosis. POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor operation No.
08-19-05-90 . . . . . . . . . . . . . . . . . . . . . . . 0.5 Hrs. A-604 Transaxle Test 49/Code 46 Test
Procedure
98-19-05-91 . . . . . . . . . . . . . . . . . . . . . . . 0.6 Hrs. A-604 Transaxle Test 50/Testing, Clutch
Volumes
09-19-05-92 . . . . . . . . . . . .. . . . .. . . . . . . . 0.3 Hrs. Transaxle Electronic Controller-Replace
FAILURE CODE: 58 - Internal defect
Diagnosis
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604
Momentary Decleration/Clutch Slippage > Page 3211
CAUTION: Do not perform this procedure unless the vehicle has 3-4 shift as described In TSB
21-01-89 Revision A.
Fault codes other than 46 and 39 must be diagnosed using regular diagnostic tests, starting with
Test # 1.
Test 49CODE 46 Test ProcedureCode 46 can only be generated by an upgraded transaxle controller P/N. If you find code 46 in
memory, the vehicle already has the upgrade - DO NOT REPLACE THE CONTROLLER.
Code 46 is primarily set in memory after the controller has made 3 unsuccessful attempts at a
proper 304 upshift. Controller logic then prevents the transaxle from any further upshift attempts
and causes it to remain in third gear until downshifts into first gears have been obtained.
Code 46 will not cause a limp-in (default to second) condition.
Faulty connections at the Turbine or Output speed sensors can result in aborted 3-4 upshifts and
set code 46 in memory. Carefully inspect the Turbine and Output speed sensor connectors for
anything that could cause an intermittent connection to the sensor (i.e., spread, bent or misaligned
terminals). If the connectors are OK, proceed with the road test below.
Road Test
Road test to confirm that code 46 can be repeated by using the following guidelines:
A. Use the DRBII to clear any fault codes before load testing.
B. Leaving the DRBII connected, road test the vehicle using the guidelines found in step # 3 of Test
50, then continue to road test with an emphasis on the 3-4 shift. Use a variety of throttle settings for
doing the 3-4 shift.
C. If transaxle performance is judged to be acceptable, return the vehicle to the owner.
D. If code 46 continues to repeat, go to Test 50 Step 7.
Test 50TESTING the A-604 Clutch Volumes
Transaxles that have 3-4 shift problems could have normal or slightly discolored fluid but no
serious clutch distress. The DRBII diagnostic tool can be
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604
Momentary Decleration/Clutch Slippage > Page 3212
used to help determine the amount of clutch wear in all A-604 clutches with the exception of
reverse.
NOTE: A transmission which has experienced a sudden clutch failure may be incapable of learning
the correct clutch volume index values. A road test of a transmission with this condition may exhibit
an upshift runaway condition, but have acceptable clutch volumes. In this case, a clutch is
obviously failing.
1. Finding A-604 clutch volumes
Connect the DRBII to the vehicle's bus diagnostic connector as shown in Transaxle Test # 1.
(Entering A-604 Diagnostics and Bus Tests)
After selecting the Transmission Section, drop down to the "SELECT TEST" level using the "YES"
key. The first select test is the "DISPLAY FAULT CODES" display. Using the "F1" key, move to the
left past the "CLEAR FAULT CODES" display until you see . . .
SELECT TEST CONTINUE PRESS F1/F2 A604 TRANSAXLE PRESS F1, F2 FOR MORE
. . . displayed on the DRBII. (NOTE: This display is not shown on the DRBII functional flow diagram
found at the beginning of this book.)
Use the "YES" key to drop down to the display shown below.
CONDITIONS SHOWN OCCUR IN REAL TIME AND MAY BE NORMAL
Press "YES" again . . .
SELECT TEST ENGINEERING DATA 1 A604 TRANSAXLE PRESS F1, F2 FOR MORE
Press the "F2" key . . .
SELECT TEST ENGINEERING DATA 2 A604 TRANSAXLE PRESS F1, F2 FOR MORE
Press the "YES" key again.
2. Understanding clutch volume values
The display on the DRBII shows the four A-604 clutches that can be examined for clutch wear.
Next to each clutch is a number that represents the volume required to fill and pressurize that
clutch circuit. The initial values that will be displayed following a battery disconnect are shown on
the next page. LR - 64
OD-89
2-4 - 48 UD - 45
NOTE: Thses are start up values and are not to be used in the actual diagnosis of the transaxle.
These numbers will change as the A-604 controller "learns" or updates clutch fill volumes due to
the normal usage and wear that occurs during the life of the transaxle.
New clutch discs will have maximum friction material present and tend to take less fluid to fill and
apply - hence the value for these clutch circuits is smaller. As the clutch ages, the clutch clearance
increases, increasing the amount of off required to fill and apply the clutch - hence the value for
these clutch circuits will be larger.
NOTE: To obtain useful clutch information on a vehicle which may have recently had its battery
disconnected, the transaxle controller must be allowed to "re-learn" each clutch circuit.
3. "Teaching" clutch volume values to the A-604 controller
A. The transaxle fluid level must be properly set.
B. The transaxle must be at normal operaing temperatures.
C. At least three constant throttle upshifts at approximately half throttle from a standing start
through the 2-3 upshift must be made. (These learn the overdrive and 2-4 clutch.)
D. At least three heavy throttle downshifts to 1st at 15 mph must be made. (These learn the
low/reverse clutch.)
E. At least three part throttle 4-3 downshifts between 40 and 50 mph must be made. (These learn
the underdrive clutch.)
4. Acceptable transaxle clutch volume value guidelines
The range of clutch volume values which have been found to be within normal wear limits are
shown below:
LR - 35 TO 85 OD - 75 TO 135
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604
Momentary Decleration/Clutch Slippage > Page 3213
2-4 - 20 TO 77 UD - 24 TO 70
5. Other factors effecting clutch volume values
1. Incorrect fluid level
2. High transaxle temperature level
3. Restricted clutch feed circuit
4. Restricted solenoid food circuit
5. Valve body leakage
6. Leaky lip seals
7. Leaky seal rings
8. Case porosity
9. Circuit leak in pump housing
10. Circuit leak in reaction shaft support
11. Damaged accumulator seal ring
12. Clogged oil filter
13. Aerated fluid
14. Faulty oil pump
15. Insufficient clutch pack clearance
16. Sticky regulator valve
17. Failed clutch return spring
NOTE: The above factors will normally be accompanied by transaxle symptoms not always related
to this procedure.
6. Interpreting clutch volume values
If all clutch volume values are still within the acceptable guidelines found in step 4, the vehicle may
be serviced by only replacing the A-604 controller with the current released. Road test the vehicle
using the instructions found in step # 8.
If any clutch volume value exceeds the upper range limit, a worn clutch pack is likely.
Refer to Technical Service Bulletin 21-08-89
7. Proper road test procedure
A. Use the DRBII to clear any fault codes before road testing.
B. Leaving the DRBII connected, road test the vehicle using the guidelines found in step # 3, then
continue to road test with an emphasis on the 3-4 shift.
C. If code 48 occurs early during the road test, erase the code and continue the road test. (A false
code 48 can sometimes set during the shift learning process.)
D. If transaxle performance is judged to be acceptable, return the vehicle to the owner
E. If Code 46 continues to repeat, verify proper turbine and output sensor connection. Repair or
replace transmission per current policy if problem persists.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction
Shaft Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction
Shaft Support - Revision > Page 3218
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction
Shaft Support - Revision > Page 3219
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction
Shaft Support - Revision > Page 3220
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210996 > Jun > 96 > A/T - Clutch
Volume Index QuIck Learn
Clutch: All Technical Service Bulletins A/T - Clutch Volume Index QuIck Learn
NO: 21-09-96
GROUP: Transmission
DATE: June 28, 1996
SUBJECT: Clutch Volume Index Quick Learn Procedure Requirement After Transaxle Overhaul Or
Replacement-41TE Transaxle
MODELS:
1989 - 1992 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1992 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1992 (AG) Daytona
1989 - 1992 (AJ) LeBaron Coupe/LeBaron Convertible
1992 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1992 (AS) Town & Country/Caravan/Voyager
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
DISCUSSION:
NOTE:
FAILURE TO PERFORM THE QUICK LEARN PROCEDURE OR BATTERY DISCONNECT, AS
DESCRIBED BELOW, AFTER A TRANSAXLE IS REPLACED OR OVERHAULED CAN RESULT
IN A LOW MILEAGE TRANSAXLE FAILURE OR POOR INITIAL SHIFT QUALITY.
The DRB III will now support the quick learn procedure for the 1989 thru 1992 Model Year Vehicles
equipped with a service replacement EATX II (with cooling fins) Transmission Control Module
(TCM) having the following part numbers:
4796121, 4796122, 4696123, 4696124.
For EATX II TCM part numbers that precede the above list, refer to Repair Procedure No. 1 of
Technical Service Bulletin 18-24-95, dated June 23, 1995.
NOTE:
1993 AND LATER 41TE/42LE TCM'S HAVE ALWAYS BEEN QUICK LEARN CAPABLE.
For EATX I (without cooling fins) TCM's, disconnecting the battery for one minute or performing the
battery disconnect function with the DRB will reset the clutch volume index (CVI) to an acceptable
range and the quick learn procedure is not required.
You must use DRB III code version 19.2 (released on Mar. 1, 1996 with TIL disc 1102) or later in
order to be able to quick learn 1989 thru 1992 model year vehicles. Quick learn must be done on
any 41TE or 42LE equipped vehicle when the transmission has been replaced or where
transmission work has been performed which affects CVI. For example, clutch pack replacements.
NOTE:
THE READING OF EATX DIAGNOSTIC TROUBLE CODES (DTC'S) AND PROPER
DIAGNOSTICS FOR 1989 THRU 1992 MODEL YEAR VEHICLES MUST BE PERFORMED
USING THE MDS AND A DRB II WITH THE APPROPRIATE CARTRIDGE OR DRB III, OR
USING A STAND ALONE DRB III WITH THE SUPER CARD INSTALLED.
AFTER PERFORMING DIAGNOSTICS YOU MUST ERASE ANY DTC'S USING ONE OF THE
TOOL CONFIGURATIONS LISTED ABOVE BEFORE PROCEEDING WITH THE QUICK LEARN
PROCEDURE.
PROCEDURE:
The EATX II quick learn procedure is required whenever a transaxle is repaired or replaced.
1. Ensure the transmission fluid level is correct.
2. Start vehicle, place the shift lever in Overdrive (OD), move the vehicle at least five feet with the
engine running and then place shifter in Neutral (N). Apply the parking brake and let the engine
idle. This purges the air in the clutch circuits to prevent erroneous clutch volume values which
could cause poor initial shift quality or a low mileage transaxle failure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210996 > Jun > 96 > A/T - Clutch
Volume Index QuIck Learn > Page 3226
3. Using the DRB III select the 1994 - 1997 Diagnostics option (1) and choose Transmissions.
4. Choose the Trans Overhauled/Replaced option and follow the instructions on the DRB III screen.
NOTE:
AFTER PERFORMING QUICK LEARN USE A PROPER DIAGNOSTIC CONFIGURATION TO
READ THE DTC'S. IF ONLY DTC 12 EXISTS, ERASE THE DTC. IF THERE ARE OTHER DTC'S,
PERFORM THE PROPER DIAGNOSTICS FOR THOSE DTC'S.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604
Momentary Decleration/Clutch Slippage
Technical Service Bulletin # 210189A Date: 890522
A/T - A604 Momentary Decleration/Clutch Slippage
Models
1989 AC & AS Bodies Equipped With A604 Transaxle
Subject
Momentary Deceleration, Default To Second Gear (Limp-In) Mode Or Excessive Clutch Slippage
During 3-4 Upshift
Index
TRANSMISSION
Date
May 22, 1989
No.
21-01-89 REVISION A
(21-19-9) P-1962 BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - CARAVAN/VOYAGER
THIS BULLETIN SERVICE TECHNICAL SERVICE BULLETIN # 21-01-89 (DATED 1/30/89)
WHICH SHOULD BE REMOVED FROM YOUR FILE.
NOTE: THIS TECHNICAL SERVICE BULLETIN IS ONLY TO BE USED IF CODES 39, 46 OR NO
CODES AT ALL ARE FOUND IN THE MEMORY.
SYMPTOM/CONDITION
- Momentary deceleration/loss of power during 3-4 shift.
- Default to 2nd gear after a 3-4 shift fault code 39: Gear
Ratio.
- Chronic inability in achieving 4th. gear.
- Excessive clutch slippage during a 3-4 shift.
These symptoms may result from an improperly functioning seal ring between the underdrive and
overdrive clutch circuits. During a 3-4 shift, fluid may leak into the underdrive circuit causing the
underdrive clutch to drag.
DIAGNOSIS
Use procedure on following pages for diagnosis. POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor operation No.
08-19-05-90 . . . . . . . . . . . . . . . . . . . . . . . 0.5 Hrs. A-604 Transaxle Test 49/Code 46 Test
Procedure
98-19-05-91 . . . . . . . . . . . . . . . . . . . . . . . 0.6 Hrs. A-604 Transaxle Test 50/Testing, Clutch
Volumes
09-19-05-92 . . . . . . . . . . . .. . . . .. . . . . . . . 0.3 Hrs. Transaxle Electronic Controller-Replace
FAILURE CODE: 58 - Internal defect
Diagnosis
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604
Momentary Decleration/Clutch Slippage > Page 3231
CAUTION: Do not perform this procedure unless the vehicle has 3-4 shift as described In TSB
21-01-89 Revision A.
Fault codes other than 46 and 39 must be diagnosed using regular diagnostic tests, starting with
Test # 1.
Test 49CODE 46 Test ProcedureCode 46 can only be generated by an upgraded transaxle controller P/N. If you find code 46 in
memory, the vehicle already has the upgrade - DO NOT REPLACE THE CONTROLLER.
Code 46 is primarily set in memory after the controller has made 3 unsuccessful attempts at a
proper 304 upshift. Controller logic then prevents the transaxle from any further upshift attempts
and causes it to remain in third gear until downshifts into first gears have been obtained.
Code 46 will not cause a limp-in (default to second) condition.
Faulty connections at the Turbine or Output speed sensors can result in aborted 3-4 upshifts and
set code 46 in memory. Carefully inspect the Turbine and Output speed sensor connectors for
anything that could cause an intermittent connection to the sensor (i.e., spread, bent or misaligned
terminals). If the connectors are OK, proceed with the road test below.
Road Test
Road test to confirm that code 46 can be repeated by using the following guidelines:
A. Use the DRBII to clear any fault codes before load testing.
B. Leaving the DRBII connected, road test the vehicle using the guidelines found in step # 3 of Test
50, then continue to road test with an emphasis on the 3-4 shift. Use a variety of throttle settings for
doing the 3-4 shift.
C. If transaxle performance is judged to be acceptable, return the vehicle to the owner.
D. If code 46 continues to repeat, go to Test 50 Step 7.
Test 50TESTING the A-604 Clutch Volumes
Transaxles that have 3-4 shift problems could have normal or slightly discolored fluid but no
serious clutch distress. The DRBII diagnostic tool can be
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604
Momentary Decleration/Clutch Slippage > Page 3232
used to help determine the amount of clutch wear in all A-604 clutches with the exception of
reverse.
NOTE: A transmission which has experienced a sudden clutch failure may be incapable of learning
the correct clutch volume index values. A road test of a transmission with this condition may exhibit
an upshift runaway condition, but have acceptable clutch volumes. In this case, a clutch is
obviously failing.
1. Finding A-604 clutch volumes
Connect the DRBII to the vehicle's bus diagnostic connector as shown in Transaxle Test # 1.
(Entering A-604 Diagnostics and Bus Tests)
After selecting the Transmission Section, drop down to the "SELECT TEST" level using the "YES"
key. The first select test is the "DISPLAY FAULT CODES" display. Using the "F1" key, move to the
left past the "CLEAR FAULT CODES" display until you see . . .
SELECT TEST CONTINUE PRESS F1/F2 A604 TRANSAXLE PRESS F1, F2 FOR MORE
. . . displayed on the DRBII. (NOTE: This display is not shown on the DRBII functional flow diagram
found at the beginning of this book.)
Use the "YES" key to drop down to the display shown below.
CONDITIONS SHOWN OCCUR IN REAL TIME AND MAY BE NORMAL
Press "YES" again . . .
SELECT TEST ENGINEERING DATA 1 A604 TRANSAXLE PRESS F1, F2 FOR MORE
Press the "F2" key . . .
SELECT TEST ENGINEERING DATA 2 A604 TRANSAXLE PRESS F1, F2 FOR MORE
Press the "YES" key again.
2. Understanding clutch volume values
The display on the DRBII shows the four A-604 clutches that can be examined for clutch wear.
Next to each clutch is a number that represents the volume required to fill and pressurize that
clutch circuit. The initial values that will be displayed following a battery disconnect are shown on
the next page. LR - 64
OD-89
2-4 - 48 UD - 45
NOTE: Thses are start up values and are not to be used in the actual diagnosis of the transaxle.
These numbers will change as the A-604 controller "learns" or updates clutch fill volumes due to
the normal usage and wear that occurs during the life of the transaxle.
New clutch discs will have maximum friction material present and tend to take less fluid to fill and
apply - hence the value for these clutch circuits is smaller. As the clutch ages, the clutch clearance
increases, increasing the amount of off required to fill and apply the clutch - hence the value for
these clutch circuits will be larger.
NOTE: To obtain useful clutch information on a vehicle which may have recently had its battery
disconnected, the transaxle controller must be allowed to "re-learn" each clutch circuit.
3. "Teaching" clutch volume values to the A-604 controller
A. The transaxle fluid level must be properly set.
B. The transaxle must be at normal operaing temperatures.
C. At least three constant throttle upshifts at approximately half throttle from a standing start
through the 2-3 upshift must be made. (These learn the overdrive and 2-4 clutch.)
D. At least three heavy throttle downshifts to 1st at 15 mph must be made. (These learn the
low/reverse clutch.)
E. At least three part throttle 4-3 downshifts between 40 and 50 mph must be made. (These learn
the underdrive clutch.)
4. Acceptable transaxle clutch volume value guidelines
The range of clutch volume values which have been found to be within normal wear limits are
shown below:
LR - 35 TO 85 OD - 75 TO 135
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604
Momentary Decleration/Clutch Slippage > Page 3233
2-4 - 20 TO 77 UD - 24 TO 70
5. Other factors effecting clutch volume values
1. Incorrect fluid level
2. High transaxle temperature level
3. Restricted clutch feed circuit
4. Restricted solenoid food circuit
5. Valve body leakage
6. Leaky lip seals
7. Leaky seal rings
8. Case porosity
9. Circuit leak in pump housing
10. Circuit leak in reaction shaft support
11. Damaged accumulator seal ring
12. Clogged oil filter
13. Aerated fluid
14. Faulty oil pump
15. Insufficient clutch pack clearance
16. Sticky regulator valve
17. Failed clutch return spring
NOTE: The above factors will normally be accompanied by transaxle symptoms not always related
to this procedure.
6. Interpreting clutch volume values
If all clutch volume values are still within the acceptable guidelines found in step 4, the vehicle may
be serviced by only replacing the A-604 controller with the current released. Road test the vehicle
using the instructions found in step # 8.
If any clutch volume value exceeds the upper range limit, a worn clutch pack is likely.
Refer to Technical Service Bulletin 21-08-89
7. Proper road test procedure
A. Use the DRBII to clear any fault codes before road testing.
B. Leaving the DRBII connected, road test the vehicle using the guidelines found in step # 3, then
continue to road test with an emphasis on the 3-4 shift.
C. If code 48 occurs early during the road test, erase the code and continue the road test. (A false
code 48 can sometimes set during the shift learning process.)
D. If transaxle performance is judged to be acceptable, return the vehicle to the owner
E. If Code 46 continues to repeat, verify proper turbine and output sensor connection. Repair or
replace transmission per current policy if problem persists.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft
Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft
Support - Revision > Page 3238
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft
Support - Revision > Page 3239
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft
Support - Revision > Page 3240
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch
Clutch: Description and Operation Input Clutch
The input clutch assembly is located directly behind the oil pump housing, and rides on the reaction
shaft support journal. The assembly consists of the following:
- Input shaft
- Input hub
- Clutch retainer
- Clutch pistons Overdrive hub Underdrive hub Three input clutches (underdrive clutch, overdrive
clutch and reverse clutch).
When the torque converter turbine turns, the input shaft, hub and clutch retainer also turn
Each of the three clutches in the input clutch assembly supply input power to a particular
component in the planetary gear train when they are hydraulically applied. They are connected to
the planetary gear-train through the overdrive hub assembly, underdrive hub assembly and the
front sun gear assembly. When any of these clutches are applied, they turn or drive a component
which is an input to the planetary gear-train.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 3243
Clutch: Description and Operation Low Reverse Clutch
The Low/Reverse (L/R) clutch is used in both low and reverse gears. The L/R clutch is located in
the back of the case, directly behind the 2-4 clutch. The L/R clutch actually shares the reaction
plate of the 2-4 clutch. It consists of steel plates, clutch discs, belleville return spring, piston and a
stamped steel piston retainer which is secured to the back of the case with screws.
The L/R clutch surrounds the outside of the front carrier assembly, and locks or grounds the front
planetary carrier/rear annulus gear assembly to the case when applied. Similar to the 2-4 clutch,
the L/R clutch is a holding element and eliminates the need for bands.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 3244
Clutch: Description and Operation Overdrive and Reverse Clutch
The Overdrive/Reverse (OD/REV) piston is between the input hub and the clutch retainer. This
piston is unique in design for the following reasons:
- It operates two separate clutches
- It is located on the outside of the clutch retainer that houses the two clutches it operates
The overdrive clutch is splined to the overdrive hub assembly, and the overdrive hub is splined to
the front carrier assembly. When the overdrive clutch is applied hydraulically, the front carrier
assembly is an input to the planetary gear-set in third (direct) and fourth (overdrive) gear ranges.
The reverse clutch is splined to the front sun gear assembly. When the reverse clutch is applied
hydraulically, it drives the front sun gear which is the input to the planetary gear-set in reverse gear
range.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 3245
Clutch: Description and Operation Underdrive Clutch
The underdrive piston, piston return spring and spring retainer are inside and to the front of the
clutch retainer. These parts control the application of the Underdrive (UD) clutch. The underdrive
clutch is named for its use in the three forward underdrive gear ranges: first, second and third.
The underdrive clutch is splined to the underdrive hub assembly. The underdrive shaft, which is
secured to the underdrive hub, is splined to the rear sun gear. When the underdrive clutch is
applied hydraulically, the rear sun gear is the input to the planetary gear-set in first, second and
third gears.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 3246
Clutch: Description and Operation 2-4 Clutch
The 2-4 clutch is used in both second and fourth gears, and is located directly behind the input
clutch assembly. The clutch consists of the following:
- Stamped steel clutch piston retainer
- Aluminum piston
- Belleville return spring
- Clutch plates
- Steel separator plates
- Reaction Plate
The above parts are held in the case with snap rings. The 2-4 clutch surrounds the outside of the
front sun gear assembly and when applied hydraulically, locks or grounds the front sun gear
assembly to the case.
The 2-4 clutch is a holding element. It is a multidisc clutch that provides more room within the
transaxle, and eliminates the need for using a band and servo as are used in other transaxle
applications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 3255
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 3256
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 3257
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 3258
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 3259
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 3260
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd 1st Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd 1st Gear Downshift > Page 3265
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1
Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1
Gear Downshift > Page 3270
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive
Upshifting/Downshifting
Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive
Upshifting/Downshifting > Page 3275
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun >
95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun >
95 > A/T - Poor Shift Quality > Page 3281
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun >
95 > A/T - Poor Shift Quality > Page 3282
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun >
95 > A/T - Poor Shift Quality > Page 3283
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun >
95 > A/T - Poor Shift Quality > Page 3284
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun >
95 > A/T - Poor Shift Quality > Page 3285
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun >
95 > A/T - Poor Shift Quality > Page 3286
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct
> 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct
> 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 3291
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov
> 92 > A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov
> 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 3296
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr >
90 > A/T - A604 Excessive Upshifting/Downshifting
Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr >
90 > A/T - A604 Excessive Upshifting/Downshifting > Page 3301
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr >
89 > A/T Reaction Shaft Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr >
89 > A/T Reaction Shaft Support - Revision > Page 3306
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr >
89 > A/T Reaction Shaft Support - Revision > Page 3307
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr >
89 > A/T Reaction Shaft Support - Revision > Page 3308
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 182188 > Dec > 88
> AIS Motor - Erratic Idle Speed In Cold Ambients
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 182188 > Dec > 88
> AIS Motor - Erratic Idle Speed In Cold Ambients > Page 3314
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 182188 > Dec > 88
> AIS Motor - Erratic Idle Speed In Cold Ambients > Page 3315
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 182188 > Dec > 88
> AIS Motor - Erratic Idle Speed In Cold Ambients > Page 3316
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Transmission Control Module > Page 3319
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3320
Control Module: Diagrams
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3321
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3322
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3323
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3324
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3325
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3326
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3327
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3328
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3329
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 3330
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > A604
Control Module: Description and Operation A604
DESCRIPTION
This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped
similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code
memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > A604 > Page 3333
Control Module: Description and Operation 41TE
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > A604 > Page 3334
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 -
Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > General Information > Page 3337
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T
> Component Information > Locations
Data Link Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T
> Component Information > Locations > Page 3341
Data Link Connector (6 - Way)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T
> Component Information > Locations > Page 3342
Data Link Connector, A/T: Description and Operation
DESCRIPTION
A light blue six-way connector with four male pins. This connector allows the DRBII access to the
CCD (Chrysler Collision Detection) Bus. With the DRBII connected here, the technician can
perform diagnostic tests on the following:
The Body Computer The Security Alarm System (SAM) The A-604 Transaxle The Electronic
Instrument Cluster The Air Suspension System
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Description and Operation
Differential: Description and Operation
The 41TE uses a helical-type ring and pinion gear set. The ring gear is bolted to the differential
case, and drives the differential case in all gear ranges. The differential case assembly consists of
the differential case and within it, two pinion gears, two side gears and a pinion mate shaft retained
with a roll pin. The differential case provides input power from the ring gear to the axle shafts
through the case, pinion shaft, pinion gears and side gears. The pinion and side gears allow the
right and left axles to rotate at different speeds while the vehicle is cornering.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note
Differential: Service and Repair Service Note
NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the
differential are the differential bearing cups and cones. If any other part fails within the differential,
you must replace the differential assembly along with the transfer shaft.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3348
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3349
Differential: Service and Repair Disassembly
The transfer shaft should be removed for differential repair and bearing turning torque checking.
Differential Cover Bolts
Remove Differential Cover
1. Remove the differential cover and bolts.
Differential Retainer Bolts
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3350
Remove Bearing Retainer
2. Remove the differential bearing retainer and bolts. 3. Using a plastic hammer, remove extension
housing/adapter plate on the right side of the transaxle.
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
bearing cone on the extension housing side.
Position Button And Collets Onto Differential And Bearing (Ring Gear Side)
Position Tool 5048 Over Button And Collets At Differential Bearing (Ring Gear Side)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3351
Remove Differential Bearing Cone (Ring Gear Side)
5. Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential
bearing cone on the bearing retainer side. 6. Using Miller Special Tool L-4518 remove the
differential bearing race from the extension housing.
Position Bearing Cup Remover Tool In Retainer
Remove Bearing Cup
7. Using Miller Special Tool 6062A remove the differential bearing race from the bearing retainer.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3352
Differential: Service and Repair Assembly
NOTE: Use MOPAR Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension
housing/adapter plate to seal to case.
Position Bearing Cone Onto Differential
1. Using Miller Special Tool L-4410, and C-4171, or equivalents, install differential bearing to
differential (extension housing side). 2. Using Miller Special Tool 5052 and C-4171, or equivalents,
install differential bearing to differential (bearing retainer side).
Differential Bearing Retainer
3. Using Miller Special Tool 6061 and C-4171, or equivalents, install differential bearing race to
bearing retainer. 4. Using Miller Special Tool L-4520 and C-4171, or equivalents, install differential
bearing to extension housing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3353
Differential: Service and Repair
Service Note
NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the
differential are the differential bearing cups and cones. If any other part fails within the differential,
you must replace the differential assembly along with the transfer shaft.
Disassembly
The transfer shaft should be removed for differential repair and bearing turning torque checking.
Differential Cover Bolts
Remove Differential Cover
1. Remove the differential cover and bolts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3354
Differential Retainer Bolts
Remove Bearing Retainer
2. Remove the differential bearing retainer and bolts. 3. Using a plastic hammer, remove extension
housing/adapter plate on the right side of the transaxle.
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
bearing cone on the extension housing side.
Position Button And Collets Onto Differential And Bearing (Ring Gear Side)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3355
Position Tool 5048 Over Button And Collets At Differential Bearing (Ring Gear Side)
Remove Differential Bearing Cone (Ring Gear Side)
5. Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential
bearing cone on the bearing retainer side. 6. Using Miller Special Tool L-4518 remove the
differential bearing race from the extension housing.
Position Bearing Cup Remover Tool In Retainer
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3356
Remove Bearing Cup
7. Using Miller Special Tool 6062A remove the differential bearing race from the bearing retainer.
Assembly
NOTE: Use MOPAR Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension
housing/adapter plate to seal to case.
Position Bearing Cone Onto Differential
1. Using Miller Special Tool L-4410, and C-4171, or equivalents, install differential bearing to
differential (extension housing side). 2. Using Miller Special Tool 5052 and C-4171, or equivalents,
install differential bearing to differential (bearing retainer side).
Differential Bearing Retainer
3. Using Miller Special Tool 6061 and C-4171, or equivalents, install differential bearing race to
bearing retainer. 4. Using Miller Special Tool L-4520 and C-4171, or equivalents, install differential
bearing to extension housing.
Checking Side Gear End Play
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3357
Checking Side Gear End Play (Extension Housing Side)
Checking Side Gear End Play (Bearing Retainer Side)
Check side gear end play whenever the differential is removed for service.
NOTE: Side gear end play must be BETWEEN 0.001 to 0.013 inch.
Differential Bearing Preload Adjustment
NOTE: Perform all differential bearing preload measurements with the transfer shaft and gear
removed.
ADJUSTMENT USING EXISTING SHIM
1. Position the transaxle assembly vertically on the support stand, differential bearing retainer side
up.
Tool L-4436 And Torque Wrench
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3358
2. Install Tool L-4436A, or equivalent into the differential and onto the pinion mate shaft. 3. Rotate
the differential at least one full revolution to ensure the tapered roller bearings are fully seated.
Checking Differential Bearings Turning Torque
4. Using Tool L-4436A, or equivalent and an inch-pound torque wrench, check the turning torque of
the differential. The turning torque should be
between
5. If the turning torque is within specifications, remove tools. Setup is complete. 6. If turning torque
is not within specifications proceed with the following steps.
a. Remove differential bearing retainer from the transaxle case. b. Remove the bearing cup from
the differential bearing retainer using Tool 6062A, or equivalent. c. Remove the existing shim from
under the cup. d. Measure the existing shim.
NOTE: If the turning torque was too high when measured, install a 0.05 mm (0.002 inch) thinner
shim. If the turning torque is was too low, install a 0.05 mm (0.002 inch) thicker shim. Repeat until 5
to 18 inch pounds turning torque is obtained. Oil Baffle is not required to be installed when making
shim selection.
e. Install the proper shim under the bearing cup. Make sure the oil baffle is installed properly in the
bearing retainer, below the bearing shim and
cup.
f. Install the differential bearing retainer using Tool 5052 and C-4171, or equivalents. Seal the
retainer to the housing with MOPAR Adhesive Sealant and torque bolts to 28 Nm (250 inch lbs.).
Checking Differential Bearings Turning Torque
7. Using Tool L-4436A, or equivalent and an inch-pound torque wrench, recheck the turning torque
of the differential. The turning torque should be
between 5 and 18 inch-pounds. Shim thickness need be determined only if any of the following
parts are replaced: Transaxle case
- Differential carrier
- Differential bearing retainer
- Extension housing
8. Attach a dial indicator to the case and zero the dial. Place the tip on the end of Special Tool
L-4436-A, or equivalent.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3359
9. Place a large screwdriver to each side of the ring gear and lift. Check the dial indicator for the
amount of end play.
CAUTION: Do not damage the transaxle case and/or differential retainer sealing surface.
Differential Bearing Shim Chart
10. Using the end play measurement that was determined, add 0.18 mm (0.007 inch). This should
give you between 5 and 18 inch pounds of bearing
preload. Refer to the Differential Bearing Shim Chart above to determine which shim to use.
11. Remove the differential bearing retainer. Remove the bearing cup. 12. Install the oil baffle.
Install the proper shim combination under the bearing cup. 13. Install the differential bearing
retainer. Seal the retainer to the housing with MOPAR Silicone Rubber Adhesive Sealant. Torque
bolts to 28 Nm
(250 inch lbs.).
14. Using Miller Special Tool L-4436-A and an inch-pound torque wrench, check the turning torque
of the differential. The turning torque should be
between 5 - 18 inch-pounds.
NOTE: If turning torque is too high install a 0.05 mm (0.002 inch) thicker shim. If the turning torque
is too low, install a 0.05 mm (0.002 inch) thinner shim. Repeat until 5 - 18 inch-pounds of turning
torque is obtained.
PRELOAD ADJUSTMENT USING GAUGING SHIM (89 - 95 ALL)
1. Remove the bearing cup from the differential bearing retainer using Tool L-4518, and remove the
existing shim from under the cup. 2. Install a .50 mm (020 inch) gauging shim into the retainer. Use
an arbor press to install the cup.
NOTE: Oil Baffle is not required when making shim selection.
3. Install the bearing retainer into the case and torque bolts to 28 Nm (250 in. lbs.). 4. Position the
transaxle assembly vertically on the support stand and install Tool C-4995 into side gear. 5. Rotate
the differential at least one full revolution to ensure tapered roller bearings are fully seated. 6.
Attach a dial indicator to the case and zero the dial indicator. Place the indicator tip on the end of
Tool L-4436. 7. Place a large screwdriver to each side of the ring gear and lift. Check the dial
indicator for the amount of end play.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Service and Repair > Service Note > Page 3360
CAUTION: Do not damage the transaxle case and/or differential cover sealing surface.
Differential Bearing Shim Chart
8. When the end play has been determined, refer to the Differential Bearing Shim Chart above for
the correct shim combination. 9. remove the differential bearing retainer. Remove the bearing cup
and the .50 mm (020 inch) gauging shim.
10 Install the proper shim combination under the bearing cup. make sure the oil baffle is installed
properly in the bearing retainer, below the bearing shim and cup.
11. Install the differential bearing retainer. Seal the retainer to the housing with MOPAR RTV
sealant. Torque bolts to 28 Nm (250 in. lbs.). 12. Using Tool C-4995 and an inch-pound torque
wrench, check the turning torque of the differential. The turning torque should be between 5 and
18 inch pounds.
NOTE: If the turning torque is too high, install a .05 mm (.002 inch) thinner shim. If the turning
torque is too low, install a .05 mm (.002 inch) thicker shim. Repeat until 5-18 inch pounds turning
torque is obtained.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission
Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > Customer Interest for Automatic
Transmission Dipstick - Dipstick Tube: > 210988 > Nov > 88 > A/T Dipstick - Does Not Seat Fully
Automatic Transmission Dipstick - Dipstick Tube: Customer Interest A/T Dipstick - Does Not Seat
Fully
Models
1989 AC- & ASBodies With The A- 604 Transaxle
Subject
Transaxle Fluid Level Dipstick Not Fully Seated
Index
TRANSMISSION
Date
November 21, 1988
No.
21-09-88
P-4913 (C21-17)
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - CARAVAN/VOYAGER
SYMPTOM/CONDITION
The transaxle dipstick may hang up and not fully seat on the transaxle fill tube on a small number
of 1989 ACand AS-body vehicles equipped with the A-604 transaxle. This condition may be caused
by the dipstick blade hanging up on the wall of the valve body transfer plate on transaxles built
before transaxle date code 97150000 or by an oversized lip at the bottom of the fill tube.
DIAGNOSIS
Insert and remove the dipstick from the fill tube five (5) times, be sure to note the fluid level each
time. The dipstick must insert freely and seat on the fill tube. The level reading must also repeat all
five (5) times. If the dipstick does not insert freely and/or the fluid level reading is not repeatable,
proceed with the repair procedure.
REPAIR PROCEDURE
This repair involves bending the end of the dipstick blade approximately 10 degrees.
1. Remove the dipstick from the fill tube. Grasp the dipstick with a pair of pliers just above the twist
at the bottom of the dipstick blade.
NOTE: THE WORDING "TRANS FLUID" ON THE DIPSTICK HANDLE MUST BE FACING
UPRIGHT.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission
Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > Customer Interest for Automatic
Transmission Dipstick - Dipstick Tube: > 210988 > Nov > 88 > A/T Dipstick - Does Not Seat Fully > Page 3369
FIGURE 1
FIGURE 2
2. Bend the bottom end of the dipstick blade up 10 degrees as shown in the Figure 1. Use the line
drawing in Figure 2 as a guide to ensure the 10 degree angle is achieved.
3. Insert the dipstick in the fill tube, start engine, check and adjust the transaxle fluid level as
required.
NOTE: THE WORDING "TRANS FLUID" ON THE DIPSTICK HANDLE MUST BE FACING
UPRIGHT WHEN INSERTING THE DIPSTICK.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No. 21-75-17-90
. . . . . . . . . . . 0.2 Hrs.
FAILURE CODE: 06 - Bent
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission
Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Automatic Transmission Dipstick - Dipstick Tube: > 210988 > Nov > 88 > A/T Dipstick - Does Not Seat Fully
Automatic Transmission Dipstick - Dipstick Tube: All Technical Service Bulletins A/T Dipstick Does Not Seat Fully
Models
1989 AC- & ASBodies With The A- 604 Transaxle
Subject
Transaxle Fluid Level Dipstick Not Fully Seated
Index
TRANSMISSION
Date
November 21, 1988
No.
21-09-88
P-4913 (C21-17)
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - CARAVAN/VOYAGER
SYMPTOM/CONDITION
The transaxle dipstick may hang up and not fully seat on the transaxle fill tube on a small number
of 1989 ACand AS-body vehicles equipped with the A-604 transaxle. This condition may be caused
by the dipstick blade hanging up on the wall of the valve body transfer plate on transaxles built
before transaxle date code 97150000 or by an oversized lip at the bottom of the fill tube.
DIAGNOSIS
Insert and remove the dipstick from the fill tube five (5) times, be sure to note the fluid level each
time. The dipstick must insert freely and seat on the fill tube. The level reading must also repeat all
five (5) times. If the dipstick does not insert freely and/or the fluid level reading is not repeatable,
proceed with the repair procedure.
REPAIR PROCEDURE
This repair involves bending the end of the dipstick blade approximately 10 degrees.
1. Remove the dipstick from the fill tube. Grasp the dipstick with a pair of pliers just above the twist
at the bottom of the dipstick blade.
NOTE: THE WORDING "TRANS FLUID" ON THE DIPSTICK HANDLE MUST BE FACING
UPRIGHT.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission
Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Automatic Transmission Dipstick - Dipstick Tube: > 210988 > Nov > 88 > A/T Dipstick - Does Not Seat Fully > Page 3375
FIGURE 1
FIGURE 2
2. Bend the bottom end of the dipstick blade up 10 degrees as shown in the Figure 1. Use the line
drawing in Figure 2 as a guide to ensure the 10 degree angle is achieved.
3. Insert the dipstick in the fill tube, start engine, check and adjust the transaxle fluid level as
required.
NOTE: THE WORDING "TRANS FLUID" ON THE DIPSTICK HANDLE MUST BE FACING
UPRIGHT WHEN INSERTING THE DIPSTICK.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No. 21-75-17-90
. . . . . . . . . . . 0.2 Hrs.
FAILURE CODE: 06 - Bent
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low
Temperature
Fluid - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low
Temperature > Page 3384
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low
Temperature > Page 3385
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low
Temperature > Page 3386
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At
Low Temperature
Fluid - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At
Low Temperature > Page 3392
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At
Low Temperature > Page 3393
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At
Low Temperature > Page 3394
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop
Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop > Page 3400
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop > Page 3406
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Page 3407
Fluid - A/T: Specifications
CAPACITY, Initial Refill*: .....................................................................................................................
....................................................................AP**
All .........................................................................................................................................................
.............................................3.8 Liters 4.0 Quarts
*With the engine at operating temperature, shift transmission through all gears. Check fluid level in
PARK and add fluid as needed **May use AF or MA when AP is not available only for "Topping
off".
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level & Condition Check
Fluid - A/T: Service and Repair Fluid Level & Condition Check
Fluid Level
The transmission and differential sump have a common oil sump with a opening between the two.
The torque converter fills in both the "P" Park and "N" Neutral positions.
Place the selector lever in "P" Park to check fluid level.
The engine should be running at idle speed for at least one minute, with the vehicle on level
ground. This will assure complete oil level stabilization between differential and transmission.
The fluid should be at normal operating temperature (approximately 82 C. or 180 F).
The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator.
Fluid Condition
Along with fluid level, it is important to check the condition of the fluid.
- When the fluid smells burned, and is contaminated with metal or friction material particles, a
complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
- If there is any doubt about its condition, drain out a sample for a double check.
Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt.
Low Fluid Level Symptoms
Low fluid level can cause a variety of conditions because it allows the pump to take in air along with
the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be
low and build up slowly.
Improper Filling Level Symptoms
Improper filling can also raise the fluid level too high.
- When the transaxle has too much fluid, the gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can
interfere with normal valve, clutch and accumulator operation.
Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a
leak.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level & Condition Check > Page 3410
Fluid - A/T: Service and Repair Fluid and Filter Change
Fluid and Filter Change
When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission
Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also
the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is
disassembled for any reason, the fluid and filter should be changed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level & Condition Check > Page 3411
Fluid - A/T: Service and Repair Fluid Drain and Refill
Procedure
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan.
2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan.
3. Install a new filter and O-ring on bottom of the valve body.
4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to
19 Nm (165 in-lbs).
5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill
tube.
6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each position, ending in the park or neutral position.
7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick.
CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil
(100F). Upper holes for hot oil (180F).
8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the
HOT region.
9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill
tube.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T Slips In Reverse At Low Temperature
Fluid Filter - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T Slips In Reverse At Low Temperature > Page 3420
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T Slips In Reverse At Low Temperature > Page 3421
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T Slips In Reverse At Low Temperature > Page 3422
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr
> 96 > A/T - Slips In Reverse At Low Temperature
Fluid Filter - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature
NO: 21-06-96
GROUP: Transmission
DATE: Apr. 26, 1996
SUBJECT: Slips In Reverse At Low Temperature
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1995 (PL) Neon
NOTE:
THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT
BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX).
SYMPTOM/CONDITION:
Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature
below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these
temperature/time conditions is considered normal.
DIAGNOSIS:
If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If
the transaxle also slips going into Drive, further diagnosis is required.
PARTS REQUIRED:
1 4659837 Piston, Low/Reverse Servo
AR 4318025 Sealant, RTV
AR 4467721 Fluid, Mopar Automatic Transmission Type 7176
1 4269649 Filter, Transaxle
1 4269671 Gasket, Transaxle Filter
REPAIR PROCEDURE:
This bulletin involves installing a revised Low/Reverse servo piston.
1. Raise the vehicle with an appropriate hoist.
2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam.
3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside
the oil pan and magnet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr
> 96 > A/T - Slips In Reverse At Low Temperature > Page 3428
4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the
transaxle oil filter and gasket from the valve body and discard (refer to Figure 1).
5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to
Figure 2).
6. Remove the neutral start/back-up lamp switch (refer to Figure 3).
7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes
from the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr
> 96 > A/T - Slips In Reverse At Low Temperature > Page 3429
8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse
servo (refer to Figures 5, 6 and 7).
9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo
assembly.
10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs.
(4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm).
11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs.
(12 Nm).
12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm).
13. Attach the parking rod to the valve body with the parking rod E-clip.
14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the
2 attaching screws to 40 in. lbs. (5 Nm).
15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and
the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to
165 in. lbs. (19 Nm).
16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the
dipstick opening.
17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector lever momentarily to each gear position. Place the
gear selector lever in either park or neutral.
18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the
ADD mark on dipstick.
19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr
> 96 > A/T - Slips In Reverse At Low Temperature > Page 3430
Labor Operation No: 21-80-10-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Fluid Drain and Refill
Fluid Filter - A/T: Service and Repair Fluid Drain and Refill
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2.
Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil
pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm
(165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602
through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and
service brakes applied, move selector lever momentarily to each
position, ending in the park or neutral position.
7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark.
CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil
(100°F). Upper holes for hot oil (180°F).
8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the
HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the
dipstick fill tube.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Fluid Drain and Refill > Page 3433
Fluid Filter - A/T: Service and Repair Fluid & Filter Change
3 Speed Automatic
Fluid and filter changes are not required for average vehicle use. Severe usage such as
commercial type usage or prolonged operation in city traffic requires that fluid be changed and
bands adjusted every 15,000 miles.
1. Raise vehicle and support vehicle. Place a suitable drain pan below transmission oil pan. 2.
Loosen transmission oil pan attaching bolts and allow fluid to drain, then remove oil pan. 3.
Replace filter and adjust bands, if necessary. 4. Install oil pan and gasket. Torque attaching bolts to
40 inch lbs. 5. Add four quarts of approved automatic transmission fluid. 6. Start engine and allow
to idle for approximately six minutes, then with parking brake applied, move selector lever
momentarily to each position.
Place selector lever in Park and check fluid level. Add fluid to bring level to Add mark.
7. Recheck fluid level after transmission has reached normal operating temperature.
4 Speed Automatic
When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic
Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the
time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a
clean, dry cloth.
If the transaxle is disassembled for any reason, the fluid and filter should be changed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Fittings
Fluid Line/Hose: Specifications
Cooler Line Fittings 110 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Fittings > Page 3438
Fluid Line/Hose: Specifications
Cooler Hose To Radiator Connector 110 in.lb
Cooler Line Connector Assembly 250 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Specifications
Fluid Pan: Specifications
Transmission Oil Pan To Case 165 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 3450
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 3451
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 3452
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 18-09-97 > Feb > 97 > Converter Clutch Vehicle Shudder on Lock Up
Fluid Pump: Customer Interest Converter Clutch - Vehicle Shudder on Lock Up
NO: 18-09-97
GROUP: Vehicle Performance
DATE: Feb. 28, 1997
SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic
Trouble Code 38
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED
OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996
TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1990 - 1991 (AQ) Chrysler TC
1989 - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Avenger/Sebring/Talon
1996 (GS) Chrysler Voyager (International Market)
1995 - 1996 (JA) Cirrus/Stratus
1996 (JX) Sebring Convertible
1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
NOTE:
DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE)
MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE
VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED
JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE
VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED
APR. 26, 1996 AND PERFORM AS NECESSARY.
Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation
and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display
screen.
DIAGNOSIS:
This shudder condition can be the result of leakage in the transmission front pump caused by a
worn pump bushing. It is sometimes accompanied by pump whine.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed.
If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary
before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 18-09-97 > Feb > 97 > Converter Clutch Vehicle Shudder on Lock Up > Page 3457
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the transmission front pump assembly and the transmission torque
converter with one that has bonded converter clutch friction material and verifying the Transmission
Control Module (TCM) part number.
1. Following the procedures outlined in the appropriate Service Manual, replace the torque
converter and the transmission front pump assembly with the parts identified in the Parts Required
section of this bulletin.
2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as
outlined in the appropriate Service Manual.
3. Verify the TCM is the appropriate part number listed:
4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above,
perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles
that do not have the appropriate TCM part number listed above, perform the Repair Procedure of
Technical Service Bulletin 21-05-96.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 21-60-05-91
1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs.
1993 - 1996 FJ,LH **4.7** Hrs.
1995 - 1996 JA,JX **5.7** Hrs.
Supplemental Labor Operation No.'s 21-00-05-63
1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 18-09-97 > Feb > 97 > Converter Clutch Vehicle Shudder on Lock Up > Page 3458
If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate
referenced Technical Service Bulletin.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 >
Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 >
Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3468
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 >
Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3469
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 >
Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3470
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 >
Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up
Fluid Pump: Customer Interest Converter Clutch - Vehicle Shudder on Lock Up
NO: 18-09-97
GROUP: Vehicle Performance
DATE: Feb. 28, 1997
SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic
Trouble Code 38
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED
OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996
TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1990 - 1991 (AQ) Chrysler TC
1989 - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Avenger/Sebring/Talon
1996 (GS) Chrysler Voyager (International Market)
1995 - 1996 (JA) Cirrus/Stratus
1996 (JX) Sebring Convertible
1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
NOTE:
DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE)
MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE
VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED
JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE
VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED
APR. 26, 1996 AND PERFORM AS NECESSARY.
Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation
and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display
screen.
DIAGNOSIS:
This shudder condition can be the result of leakage in the transmission front pump caused by a
worn pump bushing. It is sometimes accompanied by pump whine.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed.
If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary
before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 >
Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3475
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the transmission front pump assembly and the transmission torque
converter with one that has bonded converter clutch friction material and verifying the Transmission
Control Module (TCM) part number.
1. Following the procedures outlined in the appropriate Service Manual, replace the torque
converter and the transmission front pump assembly with the parts identified in the Parts Required
section of this bulletin.
2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as
outlined in the appropriate Service Manual.
3. Verify the TCM is the appropriate part number listed:
4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above,
perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles
that do not have the appropriate TCM part number listed above, perform the Repair Procedure of
Technical Service Bulletin 21-05-96.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 21-60-05-91
1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs.
1993 - 1996 FJ,LH **4.7** Hrs.
1995 - 1996 JA,JX **5.7** Hrs.
Supplemental Labor Operation No.'s 21-00-05-63
1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 >
Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3476
If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate
referenced Technical Service Bulletin.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3487
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3488
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3489
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 >
Converter Clutch - Vehicle Shudder on Lock Up
Fluid Pump: Customer Interest Converter Clutch - Vehicle Shudder on Lock Up
NO: 18-09-97
GROUP: Vehicle Performance
DATE: Feb. 28, 1997
SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic
Trouble Code 38
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED
OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996
TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1990 - 1991 (AQ) Chrysler TC
1989 - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Avenger/Sebring/Talon
1996 (GS) Chrysler Voyager (International Market)
1995 - 1996 (JA) Cirrus/Stratus
1996 (JX) Sebring Convertible
1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
NOTE:
DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE)
MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE
VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED
JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE
VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED
APR. 26, 1996 AND PERFORM AS NECESSARY.
Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation
and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display
screen.
DIAGNOSIS:
This shudder condition can be the result of leakage in the transmission front pump caused by a
worn pump bushing. It is sometimes accompanied by pump whine.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed.
If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary
before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 >
Converter Clutch - Vehicle Shudder on Lock Up > Page 3494
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the transmission front pump assembly and the transmission torque
converter with one that has bonded converter clutch friction material and verifying the Transmission
Control Module (TCM) part number.
1. Following the procedures outlined in the appropriate Service Manual, replace the torque
converter and the transmission front pump assembly with the parts identified in the Parts Required
section of this bulletin.
2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as
outlined in the appropriate Service Manual.
3. Verify the TCM is the appropriate part number listed:
4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above,
perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles
that do not have the appropriate TCM part number listed above, perform the Repair Procedure of
Technical Service Bulletin 21-05-96.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 21-60-05-91
1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs.
1993 - 1996 FJ,LH **4.7** Hrs.
1995 - 1996 JA,JX **5.7** Hrs.
Supplemental Labor Operation No.'s 21-00-05-63
1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 >
Converter Clutch - Vehicle Shudder on Lock Up > Page 3495
If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate
referenced Technical Service Bulletin.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3501
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3502
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3503
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb >
97 > Converter Clutch - Vehicle Shudder on Lock Up
Fluid Pump: All Technical Service Bulletins Converter Clutch - Vehicle Shudder on Lock Up
NO: 18-09-97
GROUP: Vehicle Performance
DATE: Feb. 28, 1997
SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic
Trouble Code 38
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED
OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996
TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1993 - 1994 (AP) Sundance/Shadow
1990 - 1991 (AQ) Chrysler TC
1989 - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Avenger/Sebring/Talon
1996 (GS) Chrysler Voyager (International Market)
1995 - 1996 (JA) Cirrus/Stratus
1996 (JX) Sebring Convertible
1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC
TRANSMISSION.
SYMPTOM/CONDITION:
NOTE:
DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE)
MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE
VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED
JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE
VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED
APR. 26, 1996 AND PERFORM AS NECESSARY.
Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation
and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display
screen.
DIAGNOSIS:
This shudder condition can be the result of leakage in the transmission front pump caused by a
worn pump bushing. It is sometimes accompanied by pump whine.
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed.
If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary
before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb >
97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3508
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the transmission front pump assembly and the transmission torque
converter with one that has bonded converter clutch friction material and verifying the Transmission
Control Module (TCM) part number.
1. Following the procedures outlined in the appropriate Service Manual, replace the torque
converter and the transmission front pump assembly with the parts identified in the Parts Required
section of this bulletin.
2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as
outlined in the appropriate Service Manual.
3. Verify the TCM is the appropriate part number listed:
4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above,
perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles
that do not have the appropriate TCM part number listed above, perform the Repair Procedure of
Technical Service Bulletin 21-05-96.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No: 21-60-05-91
1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs.
1993 - 1996 FJ,LH **4.7** Hrs.
1995 - 1996 JA,JX **5.7** Hrs.
Supplemental Labor Operation No.'s 21-00-05-63
1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs.
21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb >
97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3509
If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate
referenced Technical Service Bulletin.
FAILURE CODE: 52 - Improperly Machined
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 >
Component Information > Technical Service Bulletins > Page 3510
Fluid Pump: Description and Operation
The oil pump is located in the pump housing inside of the bell housing of the transaxle case, and is
similar to oil pumps used in other Chrysler applications. The inner gear is driven by the torque
converter impeller hub. Torque is supplied to the impeller hub by the engine crankshaft through the
flex plate and converter housing.
As the gears rotate, the clearance between the gear teeth increases in the crescent area, and
creates a suction at the inlet side of the pump. Fluid is pulled through the pump inlet from the oil
pan. As the clearance between the gear teeth in the crescent area decreases, it forces fluid into the
pump outlet. The pressurized oil from the outlet operates the torque converter, clutches and the
lubrication system. The pump is held in the housing by the reaction shaft support
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > Page 3511
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters. No provision for adjustment is provided.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > System Information > Specifications
Valve Clearance: Specifications
These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all
times.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > System Information > Specifications > Page 3514
Valve Clearance: Adjustments
This engine uses hydraulic lash adjusters. No provision for adjustment is provided.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T >
Component Information > Service and Repair
Governor: Service and Repair
1. Remove fluid pan, filter and valve body.
2. Remove bolts attaching governor to governor support, then the governor assembly from
transaxle.
3. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T >
Component Information > Specifications
Input Shaft: Specifications Speed Sensor Torque
Speed Sensor Torque
Input Speed Sensor 20 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Specifications
Output Shaft: Specifications Output Sensor Torque
Output Sensor Torque
Output Speed Sensor 20 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Technical Service Bulletins > A/T - Extreme Gearshift Effort Out of Park
Parking Pawl: Technical Service Bulletins A/T - Extreme Gearshift Effort Out of Park
Models
1989 AA, AC & AS Bodies 3.0L A/T
Subject
High Gearshift Effort Out Of Park
Index
TRANSMISSION
Date
July 10, 1989
No.
21-25-89
(C21-24-9) P-2700
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Technical Service Bulletins > A/T - Extreme Gearshift Effort Out of Park > Page 3528
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AA - SPIRIT/ACCLAIM AS CARAVAN/VOYAGER/CARAVAN C/V
SYMPTOM/CONDITION
High effort required to move the gear shift selector out of the PARK position.
PARTS REQUIRED
1 Transmission Park Guide Bracket Package PN 4549239
REPAIR PROCEDURE
Effective May 1, 1989, a new park sprag guide bracket entered production on the A-604 Ultradrive
4-speed automatic transmission. This new sprag guide bracket reduces the effort required to move
the gearshift selector out of the PARK position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Technical Service Bulletins > A/T - Extreme Gearshift Effort Out of Park > Page 3529
This new service parts park sprag guide package PN 4549239 can be used to update earlier built
A-604 transmissions to reduce the effort needed to move the transmission selector out of park.
NOTE: DO NOT INTERCHANGE PARTS BETWEEN THE OLD AND NEW ASSEMBLIES.
POLICY: For Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Description and Operation > General Information
Planetary Gears: Description and Operation General Information
The entire planetary gear-train is located behind the input clutch assembly and is inside the 2-4 and
L/R clutch assemblies. The planetary gear-train consists of two sun gears, two planetary carriers,
two annulus (ring) gears and one output shaft which is part of the rear carrier.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Description and Operation > General Information > Page 3534
Planetary Gears: Description and Operation Front Carrier Assembly
The front planetary carrier and gear annulus (ring) gear are splined together as one unit. When the
overdrive clutch is applied, it drives the front carrier assembly by the overdrive hub. When the
low/reverse clutch is applied, it holds or prevents the front carrier assembly from rotating.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Description and Operation > General Information > Page 3535
Planetary Gears: Description and Operation Rear Carrier Assembly
The rear planetary carrier, front annulus (ring) gear and output shaft are all one assembly. The rear
carrier assembly provides all output power for the transaxle assembly. In other words, all output
from the transaxle must go through the rear carrier. The lugs around the outside of the assembly
have two purposes:
- To engage the parking pawl when the driver selects park
- To generate an output speed signal used by the TCM
There are no clutches splined or connected to this unit in any way. The rear carrier assembly is
supported to the case by two tapered roller bearings, which must be set up with specific preload
and measured by turning torque.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 >
A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 >
A/T - Poor Shift Quality > Page 3545
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 >
A/T - Poor Shift Quality > Page 3546
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 >
A/T - Poor Shift Quality > Page 3547
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 >
A/T - Poor Shift Quality > Page 3548
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 >
A/T - Poor Shift Quality > Page 3549
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 >
A/T - Poor Shift Quality > Page 3550
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 >
A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 >
A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 3555
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 >
A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 >
A/T - 41TE Harsh 2-1 Gear Downshift > Page 3560
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 >
A/T - A604 Excessive Upshifting/Downshifting
Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 >
A/T - A604 Excessive Upshifting/Downshifting > Page 3565
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3571
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3572
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3573
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3574
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3575
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3576
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 3581
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 3586
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting
Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 3591
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3596
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3597
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3598
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control
Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control
Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3604
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control
Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3605
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control
Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3606
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3609
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3610
Control Module: Diagrams
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3611
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3612
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3613
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3614
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3615
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3616
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3617
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3618
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3619
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Page 3620
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > A604
Control Module: Description and Operation A604
DESCRIPTION
This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped
similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code
memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > A604 > Page 3623
Control Module: Description and Operation 41TE
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > A604 > Page 3624
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 -
Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Service and Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Service and Repair > General Information > Page 3627
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 3631
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 3632
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 3633
Transmission Control System Relay: Description and Operation
DESCRIPTION
This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to
the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay,
voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in
this mode, only second gear, reverse and neutral are available.
This relay may also be referred to as the Safety Shutdown Relay.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Position Relay, A/T > Component Information > Locations > Component Locations
Transmission Position Relay: Component Locations
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 3638
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 3647
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 3648
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 3649
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A >
Sep > 99 > A/T Pan Gasket - Reusable Design/Installation
Technical Service Bulletin # 21-05-99A Date: 990903
A/T Pan Gasket - Reusable Design/Installation
NUMBER: 21-05-99 Rev. A
GROUP: Transmission
DATE: Sep. 03, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5,
1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL
COVERAGE.
SUBJECT: Reusable Automatic Transmission Oil Pan Gasket
OVERVIEW: This bulletin announces availability and installation of a reusable automatic
transmission oil pan gasket.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
**1989** - 1993 (AG) Daytona
**1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - **2000** (FJ) Sebring/Avenger/Talon
1996 - **2000** (GS) Chrysler Voyager (European Market)
1995 - **2000** (JA) Cirrus/Stratus/Breeze
1996 - **2000** (JX) Sebring Convertible
**1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M**
1996 - **2000** (NS) Town & Country/Caravan/Voyager
**1995 - 2000 (PL) Neon**
**1997 - 2000 (PR) Prowler**
DISCUSSION:
A reusable silicone gasket has been developed to replace the RTV method of sealing the
automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change
intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is
recommended that this gasket be used in all applications.
NOTE:
THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES.
PARTS REQUIRED:
**1 05011113AA Gasket, Transmission Oil Pan, 31TH**
**1 05011114AA Gasket, Transmission Oil Pan, 42LE**
1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE
POLICY: INFORMATION ONLY
POLICY: Information Only
Installation Procedure
1. With oil pan removed from transmission case for routine service or transmission repair proceed
to step # 2.
2. Clean any residue from oil pan and magnet.
3. Replace O-ring and filter on bottom of valve body.
4. Using a plastic or wooden scraper, remove old RTV from transmission case rails.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A >
Sep > 99 > A/T Pan Gasket - Reusable Design/Installation > Page 3655
CAUTION:
ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD
GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING
THESE COMPONENTS.
5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails.
6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission
case. Tighten oil pan bolts to 19 Nm (165 in lbs.).
7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or
MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles.
CAUTION:
DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES
FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr
> 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr
> 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3660
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr
> 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3661
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr
> 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3662
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep >
99 > A/T Pan Gasket - Reusable Design/Installation
Technical Service Bulletin # 21-05-99A Date: 990903
A/T Pan Gasket - Reusable Design/Installation
NUMBER: 21-05-99 Rev. A
GROUP: Transmission
DATE: Sep. 03, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5,
1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL
COVERAGE.
SUBJECT: Reusable Automatic Transmission Oil Pan Gasket
OVERVIEW: This bulletin announces availability and installation of a reusable automatic
transmission oil pan gasket.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
**1989** - 1993 (AG) Daytona
**1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - **2000** (FJ) Sebring/Avenger/Talon
1996 - **2000** (GS) Chrysler Voyager (European Market)
1995 - **2000** (JA) Cirrus/Stratus/Breeze
1996 - **2000** (JX) Sebring Convertible
**1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M**
1996 - **2000** (NS) Town & Country/Caravan/Voyager
**1995 - 2000 (PL) Neon**
**1997 - 2000 (PR) Prowler**
DISCUSSION:
A reusable silicone gasket has been developed to replace the RTV method of sealing the
automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change
intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is
recommended that this gasket be used in all applications.
NOTE:
THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES.
PARTS REQUIRED:
**1 05011113AA Gasket, Transmission Oil Pan, 31TH**
**1 05011114AA Gasket, Transmission Oil Pan, 42LE**
1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE
POLICY: INFORMATION ONLY
POLICY: Information Only
Installation Procedure
1. With oil pan removed from transmission case for routine service or transmission repair proceed
to step # 2.
2. Clean any residue from oil pan and magnet.
3. Replace O-ring and filter on bottom of valve body.
4. Using a plastic or wooden scraper, remove old RTV from transmission case rails.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep >
99 > A/T Pan Gasket - Reusable Design/Installation > Page 3668
CAUTION:
ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD
GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING
THESE COMPONENTS.
5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails.
6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission
case. Tighten oil pan bolts to 19 Nm (165 in lbs.).
7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or
MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles.
CAUTION:
DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES
FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3669
Seals and Gaskets: By Symptom
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3670
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3671
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3672
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3673
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3674
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3675
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3676
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Page 3677
Seals and Gaskets: Service and Repair
Remove Oil Pump Seal
Install Oil Pump Seal
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the
transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3690
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3691
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3692
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 3698
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 3699
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 3704
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 3705
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 3706
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production
Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production
Change > Page 3712
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production
Change > Page 3713
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and
Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and
Pressure Switch Assembly > Page 3716
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and
Pressure Switch Assembly > Page 3717
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and
Pressure Switch Assembly > Page 3718
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 3721
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission
Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission
Range Sensor > Page 3724
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission
Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission
Range > Page 3727
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission
Range > Page 3728
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission
Range > Page 3729
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3738
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3743
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3744
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3745
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 3751
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3756
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3757
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3758
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3759
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor
Transmission Speed Sensor: Description and Operation Output Speed Sensor
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor >
Page 3762
Transmission Speed Sensor: Description and Operation Turbine Speed Sensor
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque
convertor turbine).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3763
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation
Transmission Temperature Sensor/Switch: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop
Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop > Page 3775
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul >
96 > A/T - Ratcheting Sound When Coming To Stop
Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul >
96 > A/T - Ratcheting Sound When Coming To Stop > Page 3781
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Technical Service Bulletins > Page 3782
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Technical Service Bulletins > Page 3783
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Selector Shaft, A/T > Component Information > Service and Repair
Selector Shaft: Service and Repair
REMOVAL
1. Remove shift cable from lever.
2. Loosen the lever mounting bolt. Do not remove bolt (not necessary). 3. Pull up on lever and
remove.
INSTALLATION
For installation, reverse removal procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair
Shift Cable: Service and Repair
REMOVAL
1. Remove cable eyelet attachment from transaxle operating lever pin.
2. Using pliers, squeeze ears of cable conduit attachment at mounting bracket and push through
hole to remove. 3. At the steering column attachment, remove the cable eyelet attachment from the
shift lever pin. 4. Using pliers, squeeze ears of cable attachment at mounting bracket then push
through hole to remove. 5. Unseat the dash grommet and remove the cable from the vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair > Page 3791
6. Remove the under instrument panel silencer.
INSTALLATION
1. Install cable into steering column attachment bracket. Verify conduit ears are fully engaged.
Verify cable does not interfere with brake pedal
actuation.
2. Attach cable eyelet fitting onto shift lever pin. 3. Insert transaxle end of cable through dash panel
hole and fully seat grommet 4. Install instrument panel silencer. Verify gearshift cable is routed
through the slot in the silencer.
CAUTION: Failure to route the cable properly at the silencer may cause brake pedal interference.
5. Attach transaxle end of cable to the mounting bracket on the transaxle. Assure the conduit
attachment ears are fully seated. 6. Attach cable eyelet fitting onto the transaxle operating lever. 7.
Complete adjustment using the gearshift cable adjustment procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T >
Component Information > Specifications > Cable and Pinion
Speedometer Gear, A/T: Specifications
Speedometer Cable 35 ft.lb
Speedometer Pinion Bolt 60 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T >
Component Information > Specifications > Cable and Pinion > Page 3796
Speedometer Gear, A/T: Specifications
Speedometer To Extension Bolt 60 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T >
Component Information > Specifications > Page 3797
Speedometer Gear, A/T: Service and Repair
1. Remove bolt and washer assembly securing speedometer pinion adapter in extension housing.
2. With cable housing connected, carefully work adapter and pinion out of extension housing.
3. Remove retainer and pinion from adapter.
4. If transmission fluid is found in cable housing, install new speedometer pinion and seal
assembly. If fluid is found leaking between cable and adapter, replace O-ring on cable.
5. Prior to installation, ensure adapter flange and mating areas on extension housing are clean.
6. Install pinion on adapter with new O-ring, then the retainer on pinion and adapter. Ensure
retainer is properly seated.
7. Install bolt and washer assembly and torque to specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Description and Operation > Front Sun Gear Assembly
Sun Gear: Description and Operation Front Sun Gear Assembly
The front sun gear assembly rides in the center of the front carrier, and is welded to the center of
two hubs that are arranged back to back. Each of the hubs are splined to a clutch. The front-most
hub is splined to the reverse clutch which turns the front sun gear when it is applied. The rearward
hub is splined to the 2-4 clutch which prevents the front sun gear from turning when it is applied.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Description and Operation > Front Sun Gear Assembly > Page 3802
Sun Gear: Description and Operation Rear Sun Gear
The rear sun gear is located in the center of the rear carrier assembly. There are two thrust
bearings located on either side of the sun gear. When the underdrive clutch is applied, it drives the
rear sun gear through the underdrive hub and shaft.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve
Cable/Linkage, A/T > Component Information > Adjustments > Rod Adjustment - Torqueflite
Throttle Valve Cable/Linkage: Adjustments Rod Adjustment - Torqueflite
Fig. 3 Throttle cable linkage
1. Ensure engine is at normal operating temperature.
2. Loosen adjustment swivel lock screw, Fig. 3.
3. To ensure Proper adjustment, swivel must be free to slide along flat end of throttle rod so that
preload spring action is not restricted. Disassemble and clean or repair parts as necessary.
4. Hold transaxle throttle lever firmly toward engine against its internal stop and torque swivel lock
screw to 100 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve
Cable/Linkage, A/T > Component Information > Adjustments > Rod Adjustment - Torqueflite > Page 3807
Throttle Valve Cable/Linkage: Adjustments Throttle Control Cable Adjustment
Fig. 3 Throttle cable linkage
1. Ensure engine is at normal operating temperature.
2. Loosen adjusting bracket lock screw, Fig. 3.
3. Position bracket with both alignment tabs touching transaxle cast surface.
4. Torque adjusting bracket lock screw to 105 inch lbs.
5. Release cross-lock on cable assembly by pulling upward.
6. To ensure proper adjustment, cable must be free to slide completely towards engine, against its
stop, after cross-lock is released.
7. Move transaxle throttle control lever fully clockwise against its internal stop, then press
cross-lock downward into locked position.
8. Connect choke, if disconnected, then test cable operation for freedom by moving transaxle
throttle lever forward, then slowly release it to ensure full return.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications
Torque Converter: Specifications
A-413 / A-670
Flex plate to torque converter bolts
......................................................................................................................................................... 74
Nm ( 55 ft-lbs )
A-604
Drive plate to torque converter bolts
....................................................................................................................................................... 94
Nm ( 70 ft-lbs )
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications > Page 3811
Torque Converter: Description and Operation
The torque converter is similar in function and design to other Chrysler torque converters. The
torque converter clutch engages or disengages the turbine assembly to the impeller housing. The
application of the converter clutch is controlled electronically by the solenoid assembly and valve
body. The torque converter transmits torque from the engine crankshaft to the input shaft of the
transaxle.
The torque converter clutch may engage (under the right conditions) in either 2nd, 3rd or 4th gears.
The torque converter clutch engagement is normally very smooth and may even be undetectable
by the driver. There are two types of torque converter engagement: partial and full engagement.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch
Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging
Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch
Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3820
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch
Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3821
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch
Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3822
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter
Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging
Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter
Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3828
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter
Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3829
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter
Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3830
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Component Locations
Torque Converter Clutch Solenoid: Component Locations
Part Throttle Unlock Solenoid (3speed)
LH Side Of Engine Compartment 3 Speed Automatic
RH Side Of Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Component Locations > Page 3833
Applicable to: 3 Speed A-413 Automatic Transaxle
4 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Component Locations > Page 3834
Electrical Connections, 3 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Page 3835
Torque Converter Clutch Solenoid: Description and Operation
Part Throttle Unlock Solenoid (3 Speed Automatic)
This solenoid is controlled by the engine controller. The engine controller applies and removes the
ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque
converter is only locked up when the transmission is in direct drive and when the throttle position is
not fluctuating. If the engine controller receives a signal from the throttle position sensor that an
increase or decrease in throttle is needed (when the transmission gear selector is in direct drive),
the engine controller will disengage the part throttle solenoid causing the lock-up torque converter
to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 3839
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 3840
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 3841
Transmission Control System Relay: Description and Operation
DESCRIPTION
This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to
the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay,
voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in
this mode, only second gear, reverse and neutral are available.
This relay may also be referred to as the Safety Shutdown Relay.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve
Technical Service Bulletin # 281T Date: 891201
Original TSB
No. 281T
December, 1989 To:
All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 281T Transmission Oil Cooler Bypass Valve
Models: 1988 and 1989 S-Body Models Equipped With Heavy Duty Trailer Tow Package -Plymouth Voyager and Grand Voyager, Dodge Caravan, Grand Caravan, Caravan C/V and Grand
Caravan C/V
The listed model vehicles equipped with the trailer tow package may experience restricted
transmission fluid flow through the oil cooler at low temperature (-15 degrees F and below). This
may result in lack of lubrication to the transmission and possible transmission failure.
To ensure adequate lubrication, a transmission oil cooler bypass valve system must be installed.
Important: Some of the involved vehicles may still be in dealer inventory. Be sure to complete the
service on these vehicles before delivery to customers.
Because of the cold weather nature of the condition, only those vehicles invoiced to dealers in the
Northern U.S. are included in this notification and service action. The following Zones are included:
Boston, Chicago, Denver, Detroit, Kansas City, Milwaukee, Minneapolis, Pittsburgh and Syracuse;
also the State of Alaska.
Parts distribution and Vehicle Lists will be limited to these dealers. However, vehicles in other
areas are eligible for the repair as needed to meet cold weather operation requirements upon
owner request.
Details of this service action are explained in the following sections. As an additional service aid, a
videotape demonstrating the service procedure is included in the December, 1989 Master Tech
program.
Vehicle, Parts, and Owner Info.
VEHICLE LIST
Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location)
will receive a listing of them with this letter, arranged in Vehicle Identification Number (VIN)
sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging
for service of involved vehicles.
Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of
this letter by Compak Mall for use in performing the service on involved vehicles upon request.
Parts
Parts packages, PN C3940361, are being shipped free of charge to all involved dealers for service
of affected vehicles. Each dealer to whom involved vehicles were invoiced (or the current dealer at
the same location) will receive enough parts packages to service 75% of those vehicles. Parts
(Continued)
Each recall parts package contains the following components:
Quantity Description
(1) Bypass valve
(2) Brass tees
(4) Nipple connectors
(4) Hose clamps
(1) Foam tube
(1) Tie strap
(1) Tie strap (with "push-in" retainer)
Also included in each package is an instruction summary for convenient reference by the servicing
technician.
Additional parts may be ordered without charge from Parts Depots if required. Order only as
needed for scheduled repairs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3850
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for the service with their dealers at the
earliest possible date. A copy of the owner notification letter is attached.
Enclosed with each owner notification is an Owner Recall Notification Form # 83- 295-0019. The
involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Service Procedure
Figure 1
Prior to performing this service, it is important to understand that the bypass valve, to function
properly, must be located and connected to the transmission oil cooler hoses in the correct oil flow
direction (Figure 1).
Figure 2
1. Using Chrysler Mopar Thread Sealant PN 4318034 or equivalent at all connections, assemble
the supplied bypass valve, tees and connectors as shown in Figure 2. Tighten the tees and
connectors to 12 N-m (110 in.lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3851
Figure 3
2. Raise vehicle on hoist for working access to the transmission oil cooler hoses routed along the
inboard side of the left front frame rail.
3. Measure 5-1/2 inches rearward from the front edge of the frame rail and 2 inches up from the
bottom of rail (Figure 3) and drill a 1/4 inch diameter hole in the rail.
Figure 4(3-Speed Transmission)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3852
Figure 5(4-Speed Transmission)
4. Referring to Figures 4 and 5, follow the cooler hoses routed from the transmission to clearly
identify the cooler "in" hose.
Figure 6
5. Place an oil pan under the vehicle to catch fluid leakage. (Oil loss will be minimal.)
6. Pushing the cooler hoses against the frame, cut the cooler "in" hose at the drilled hole (Figure 6)
and allow oil to drain.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3853
Figure 4(3-Speed Transmission)
Figure 5(4-Speed Transmission)
IMPORTANT: Illustration is typical of 4-speed hose routing. 3-speed hose routing differs; therefore
it is important to identify the cooler "in" and "out" hoses per Figures 4 and 5.
Figure 1
7. Slide 2 of the supplied clamps over the hose ends and install the cooler "in" end connectors of
the bypass valve assembly to the cut hose ends.
NOTE: Refer to Figure 1 to identify the male (pipe nipple) end of the valve. This end of the
assembly.must be connected to the cooler "in"
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3854
hose.
Figure 7(3-Speed Transmission Installation)
Figure 8(4-Speed Transmission Installation)
8. Cut the other hose (cooler "out") at the drilled hole, allow oil to drain, and connect the hose ends
to the valve assembly connectors in the
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3855
same manner.
9. Cut the supplied foam tube and wrap it around the bypass valve (Figures 7 and 8).
10. Tighten the supplied "push-in" tie strap around the foam tubing and cut off excess strap.
11. Engage the push-in tie strap in the drilled 1/4 inch hole (Figures 7 and 8).
NOTE: Because the hoses and hose routing differ on the 3-speed and 4- speed transmission, the
valve assembly must be positioned differently for each -- valve mounted vertically for the 4-speed
and at an angle for the 3- speed.
12. Tighten all hose clamps to 2 N-m (15 in.lbs).
13. Install the other supplied tie strap to secure the assembly to the frame rail (Figures 7 and 8).
Cut off excess strap.
14. Check and, if necessary, adjust transmission oil level.
Completion Information
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted by DIAL dealers on the DIAL
System. Non DIAL dealers may submit WROS. Claims submitted will be used by Chrysler to record
recall service completions and provide dealer payments.
Enter only one VIN per claim on a WRO. Fill in the labor operation number and time allowance and
write on the WRO "Customer Satisfaction Notification # 281T --Transmission Oil Cooler Bypass
Valve." Do not enter other service claims on the same WRO. Use the following labor operation
number and time allowance:
Labor Operation Time
Number Allowance
Install transmission oil cooler bypass valve. 21281282 0.5 Hour
Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall
claim processing instructions.
Parts Return
Not applicable.
Vehicle Not Available
If a vehicle is not available for this service for a known reason, let us know by filling outthe
pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe
the reason on a postcard and mall to:
Chrysler Motors 416-15-19 Recall Coordination P.O. Box 1919 Detroit, Michigan 48231-9986
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Customer Letter
CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE
Dear Chrysler Motors Vehicle Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a
free repair service to owners of certain 1988 and 1989 model vehicles equipped with the heavy
duty trailer tow package. Included are the Plymouth Voyager and Grand Voyager, Dodge Caravan,
Grand Caravan, Caravan C/V and Grand Caravan C/V. Your vehicle, whose Vehicle Identification
Number is shown on the enclosed form, is included in this offer. This service and the required parts
as described in this letter will be provided without charge.
The service is needed to prevent possible transmission damage in extremely cold weather resulting
from restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this
important service without delay.
To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply
to the transmission at all times. The work will take less than one hour to complete. However,
additional time may be required depending on how service appointments are scheduled and
processed. To arrange for this service:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3856
^ Contact your dealer as soon as possible to schedule an appointment for the free service.
^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and
give it to your dealer. The form identifies the vehicle and condition for which service is required.
If you have any problem obtaining the needed service, please contact the Chrysler
Zone Service Office in your area. (It is listed under "Service Assistance" in your Operator's
Manual.) A Zone representative will arrange for prompt servicing of your vehicle.
We regret any inconvenience that this action may cause you. However, we believe that this special
service will help to ensure your continuing satisfaction with your Voyager or Caravan.
Thank you for your attention to this important matter.
SERVICE AND PARTS OPERATIONS CHRYSLER MOTORS CORPORATION
Supplement # 1
No. 281T
March, 1990 SUPPLEMENT CUSTOMER SATISFACTION NOTIFICATION # 281 -TRANSMISSION OIL COOLER BYPASS VALVE: THIS PROGRAM HAS BEEN EXTENDED TO
INCLUDE ADDITIONAL VEHICLES IN SPECIFIED FRIGID CLIMATE STATES To:
All Dodge and Chrysler-Plymouth Dealers in Involved Zones; All Regional and Zone Service and
Parts Managers
Subject: Customer Satisfaction Notification # 281T -- Transmission Oil Cooler Bypass Valve -Additional Vehicles in Specified States
Models: The Following Additional Models Equipped With the A604 4-Speed Automatic
Transmission and External Transmission Oil-To-Air Cooler:
^ 1989 AC-Body Cars -- Chrysler New Yorker, New Yorker Landau and Dodge Dynasty
^ 1989 AS-Body Models Without Heavy Duty Trailer Tow Package - - Voyager, Grand Voyager,
Caravan, Grand Caravan, Caravan CN Van and Extended Van
^ 1990 AC & AY-Body Cars -- Chrysler Salon, New Yorker Landau, New Yorker Fifth Avenue,
Imperial and Dodge Dynasty
^ 1990 AS-Body Models Equipped With Heavy Duty Trailer Tow Package -- Voyager, Grand
Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended Van
^ 1990 AS Body Chrysler Town & Country
Location: This Service Action Applies Only to Vehicles in the Following Frigid Climate States:
^ Minneapolis Zone -- Minnesota, North Dakota, South Dakota
^ Milwaukee Zone -- Wisconsin, Michigan (U.P.)
^ Detroit Zone -- Michigan
^ Denver Zone -- Montana, Wyoming
^ Portland Zone -- Alaska
Reference: Dealer notification letter # 281T, December, 1989, for 1988-9 AS-Body vehicles with
heavy duty trailer tow package and located in Northern U.S.
The initial notification for recall # 281T involved 1988 and 1989 model year AS-Body vehicles
equipped with trailer tow and operating in cold climates. The action was taken to eliminate the
potential for transmission damage due to oil flow restriction through the oil cooler during cold
weather.
The recall population is now being expanded to also include certain additional 4- speed
transmission equipped AS, AC and AY-Body vehicles with external transmission oil-to-air coolers
operating in frigid climate regions. Note:
Vehicles already equipped with oil cooler bypass valve systems under Technical Service Bulletin #
21-28-89 do not require further service for this condition.
All service requirements for the additional vehicles are the same as for the original Recall # 281T
except as noted in the following sections. A copy of the original dealer notification letter of
December, 1989 is enclosed for your reference.
Parts
The same parts package used for previously involved vehicles, PN C3940361, is required for the
added models. Parts sufficient to repair 75% of the involved vehicles will be shipped free of charge
to involved dealers as supplies become available.
Note: For 1990 AS-Body models only, an additional bracket, PN C3940385, is require to complete
the recall package installation. Six of these
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3857
brackets will be provided free of charge to involved dealers for use as required. Additional brackets,
if needed, are available for ordering from the parts depot.
Owner Notification and Service Scheduling
Owners will be notified of the service requirement aftershipment of the recall parts to involved
dealers.
Service Procedure
^ The procedure for installing the bypass valve assembly on 1989 AS-Body models without trailer
tow is the same as shown in the instructions already provided in the dealer recall notification letter
(# 281T) for trailer tow vehicles.
^ For 1989 AC-Body models, the procedure is the same as previously described for recall # 281T
except there is no drilling required (procedure step 3). A 1/4 inch hole already exists in the frame
rail for the push-in tie strap to retain the valve assembly.
^ The procedure for 1990 AC and AY-Body models is also the same as previously described for
recall # 281T except as follows:
FIGURE 11990 AC AND AY-BODY CARS
- A plate is attached to the frame rail where the valve assembly is to be located. Therefore, a 1/4
inch hole must be drilled through the plate (at the location shown in Figure 1 of this letter to
accommodate the pushin tie strap.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3858
FIGURE 21990 AC AND AY-BODY CARS
- Install the other retaining tie strap by routing the strap through the two existing frame holes as
shown in Figure 2.
Figure 31990 AS-Body with External Cooler (Trailer Tow or Town & Country)
^ Installation of the bypass valve assembly on 1990 AS-Body models differs as follows (see Figure
3):
- To install the valve assembly, cut the cooler hoses in line with the center of the large hole in the
bottom of the frame.
- Install bracket PN C3940385 to retain the upper cooler hose, using the existing lower battery tray
attaching bolt.
- Since the valve assembly will be clear of the frame rail with this installation, the anti-rattle foam
tube and tie straps are not required.
Important: Remember that the bypass valve must be installed in the proper flow direction. Be sure
to identify the transmission fluid out (outlet and in (inlet) fittings at the transmission as shown in
Figure 5 of the original Recall # 281T service procedure. Then follow the hoses from the
transmission to the valve mounting location to ensure that the valve is attached properly to the "in"
and "out" hoses as shown in Figure 8 of the original recall service procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3859
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE
Dear Chrysler Corporation Vehicle Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a
free service at this time to owners of certain 1989 and 1990 model vehicles equipped with 4-speed
automatic transmissions. The vehicle whose Vehicle Identification Number is shown on the
enclosed form is included in this offer. The service and requiredpartsas describedin this letter will
be provided to you without charge.
This service will prevent possible transmission damage in extremely cold weather resulting from
restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this
important service without delay.
To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply
to the transmission at all times. If your vehicle has already had this service performed, please
disregard this notice. Otherwise, to obtain this service:
^ Contact your dealer promptly to schedule an appointment for the free service.
^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and
give it to your dealer. The form identifies the vehicle and condition for which service is required.
The work will take less than one hour to complete. However, additional time may be required
depending on how service appointments are scheduled and processed.
If you have any problem obtaining the needed service, please contact the Chrysler Zone Service
Office in your area. (it is listed under "Service Assistance" in your Operator's Manual.) A Zone
representative will arrange for prompt servicing of your vehicle.
We regret any inconvenience that this action may cause you. However, we believe that this special
service will help to ensure your continuing satisfaction with your Chrysler product.
Thank you for your attention to this important matter.
Supplement # 2
NO. 281T
October, 1990 SUPPLEMENT # 2 CUSTOMER SATISFACTION NOTIFICATION # 281T -TRANSMISSION OIL COOLER BYPASS VALVE: THIS PROGRAM HAS BEEN EXTENDED TO
INCLUDE ADDITIONAL 1990 MODEL YEAR VEHICLES IN SPECIFIED FRIGID CLIMATE
STATES AND TO REVISE PARTS AND PROCEDURES FOR SPECIFIED MODELS To:
All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 281T -- Transmission Oil Cooler Bypass Valve -Additional 1990 Vehicles in Specified States and Revised Parts/Procedures
Models: All Following Vehicles Equipped With A604 4-Speed Automatic Transmission and Locate
in States Specified Below:
^ 1989 AC -- Chrysler New Yorker, New Yorker Landau and Dodge Dynasty
^ 1990 AC & AY -- Chrysler Salon, New Yorker Landau, New Yorker Fifth Avenue, Imperial and
Dodge Dynasty
^ 1990 AS -- Voyager, Grand Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended
Van -- Equipped With Heavy Duty Trailer Tow Package
^ 1990 AS -- Chrysler Town & Country -- All
Location: This Service Action Applies Only to Vehicles in the Following Frigid Climate States:
^ Minneapolis Zone -- Minnesota, North Dakota, South Dakota
^ Milwaukee Zone -- Wisconsin, Michigan (U.P.)
^ Detroit Zone -- Michigan
^ Denver Zone -- Montana, Wyoming
^ Portland Zone -- Alaska
Reference: ^ Dealer notification letter # 281T, December, 1989. ^
Dealer notification letter # 281T supplement, March, 1990.
The Recall # 281T Supplement dated March, 1990 applied to specific 1989 and 1990 model year
vehicles built throu h February 11, 1990 and located in frigid climate states. The service action is
nowleing extended to include 1990 model year vehicles in the same states which were built from
February 12, 1990 through the end of 1990 model year production.
Important: Some of the involved vehicles may still be in dealer stock. Be sure to complete the
service on these vehicles before retail delivery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3860
Revised parts packages have been developed for 1989 and 1990 model year AC/AYBody cars and
for 1990 AS-Body minivans and wagons. These packages contain preassembled bypass valve and
oil cooler hose components. All 1988 and 1989 AS-Body vehicles will continue to use the previous
parts package. Details of this service action are explained in the following sections.
Note: Vehicles already equipped with oil cooler bypass valve systems under Technical Service
Bulletin # 21-28-89 or previously serviced for this recall with the original parts package do not
require further service for this condition.
Vehicle List
Each dealer to whom additional later-built 1990 model year vehicles were invoiced (or the current
dealer at the same location) will receive a vehicle list with this letter arranged in Vehicle
Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for
dealer reference in arranging for service of involved vehicles.
Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of
this letter by Compak Mail for use in performing the service on involved vehicles upon request.
Parts
Parts packages are being distributed free of charge to all involved dealers for service of affected
vehicles. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same
location) will receive enough parts packages to service 50% of those vehicles.
Two new parts packages have been released for specific models as follows: Included in each
package is an instruction summary for convenient reference by the servicing technician.
Note: For 1988 and 1989 AS-Body vehicles involved in the original Recall # 281T notification of
December, 1989, and the Recall # 281T Supplement of March, 1990, continue to use the original
parts package, PN C3940361.
Additional parts may be ordered without charge from Parts Depots if required. Order only as
needed for scheduled repairs.
Owner Notification and Service Scheduling
All involved owners of additional 1990 vehicles who are known to Chrysler are being notified of the
service requirement by first class mail. They are requested to schedule appointments for the
service with their dealers at the earliest possible date. A copy of the owner notification letter is
attached.
Enclosed with each owner notification is an Owner Recall Notification Form # 83-295-0019. The
involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Service Procedure
A. 1989 and 1990 AC/AY-Body Passenger Cars
1. Place an oil pan under the vehicle to catch fluid leakage (oil loss will be minimal).
2. Disconnect the existing cooler hoses from the fittings at the transmission and at the external oil
cooler mounted at the front of the radiator. Save the clamps for reinstallation.
3. Install the supplied valve and hose assembly (PN C3940405) in place of the removed hoses as
follows.
Note: The hoses on the new assembly are banded together with tape and the ends are pre-molded
to align them for installation to the appropriate transmission and cooler fittings. Do not disturb the
tape wrappings.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3861
Figure 1
Vehicles not equipped with Bendix Anti-Lock Brake System -Install the supplied bracket on the valve (with the bracket mounting holes toward the front as shown
in Figure 1). Loosely attach the bracket to the left front frame rail with the supplied screw, using the
existing hole in the rail.
Figure 2
Figure 3
^ Vehicles equipped with Bendix Anti-Lock Brake System (ABS) -There is an existing cooler line clip at the ABS controller module mounted to the left front frame rail
(Figure 2). Use this existing clip to support the valve and hose assembly as shown in Figure 3.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3862
Figure 4
Figure 5
^ All Vehicles -- Attach the hoses to the fittinqs at the external oil cooler (Figure 4) and at the
transmission (Figure 5). Secure with the original clamps.
^ Tighten the valve support bracket screw (non ABS cars) or clip screw (Bendix ABS equipped
cars).
^ Start the engine and check for leaks.
^ Check and, if necessary, adjust the transmission oil level.
Figure 2
Figure 3
B. 1990 AS-Body Mini Vans/Wagons With Heavy Duty Trailer Tow
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3863
1. Place an oil pan under the vehicle to catch fluid leakage (oil loss will be minimal).
2. Disconnect the existing cooler hoses from the fittings at the base of the radiator (Figure 2) and
from the transmission fittings (Figure 3). Save the clamps for reinstallation.
3. Install the supplied valve, hose and bracket assembly (PN C3940406) in place of the removed
hoses as follows.
Note: The hoses on the new assembly are banded together with tape and the ends are pre-molded
to align them for installation to the appropriate transmission and cooler fittings. Do not disturb the
tape wrappings.
Figure 1
^ Support the valve and hose assembly by loosely attaching the valve support bracket to the left
front frame rail with the supplied screw, using the existing hole in the rail (Figure 1).
Figure 2
^ Attach the hoses to the fittings at the base of the radiator and secure with the original clamps
(Figure 2).
Important: Note that bolh hoses do not attach to the lower radiator tank fittings. As shown in Figure
2, one hose attaches to the lower radiator tank fitting and the other hose attaches to the external
cooler tube.
Figure 3
^ ^ Attach the hoses to the transmission fittings and secure with the original clamps (Figure 3).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3864
^ ^ Tighten the valve support bracket screw.
^ ^ Start engine and check for leaks.
^ ^ Check and, if necessary, adjust the transmission oil level.
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record recall service completions and provide dealer
payments. Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
^ Install transmission oil cooler 21281282 0.5 Hour bypass valve -- 1990 AS-Body with heavy duty
trailer tow.
Note: This is the same labor operation number and time allowance as specified for vehicles
involved in the original recall # 281T notification of December, 1989.
^ Install transmission oil cooler 21281283 0.3 Hour bypass valve -- 1989 and 1990 AC/AY-Body
cars
Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H, for complete recall
claim processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for this service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe
the reason on a postcard and mail to:
Chrysler Corporation 416-15-19 Recall Coordination P.O. Box 1919 Detroit, Michigan 48231-9986
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE
Dear Chrysler Motors Vehicle Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a
free service at this time to owners of certain 1990 model vehicles equipped with 4-speed automatic
transmissions. The vehicle whose Vehicle Identification Number is shown on the enclosed form is
included in this offer. The service and required parts as described in this letter will be provided to
you without charge.
This service will prevent possible transmission damage in extremely cold weather resulting from
restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this
important service without delay.
To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply
to the transmission at all times. If your vehicle has already had this service performed, please
disregard this notice. Otherwise, to obtain this service:
^ Contact your dealer promptly to schedule an appointment for the free service.
^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and
give it to your dealer. The form identifies the vehicle and condition for which service is required.
The work will take less than one hour to complete. However, additional time may be required
depending on how service appointments are scheduled and processed.
If you have any problem obtaining the needed service, please contact the Chrysler Zone Service
Office in your area. (It is listed under "Service Assistance" in your Operator's Manual.) A Zone
representative will arrange for prompt servicing of your vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass
Valve > Page 3865
We regret any inconvenience that this action may cause you. However, we believe that this special
service will help to ensure your continuing satisfaction with your Chrysler product.
Thank you for your attention to this important matter.
Dealer Instructions
IMPORTANT
DEALER INSTRUCTIONS
CUSTOMER SATISFACTION NOTIFICATION # 281T, SUPPLEMENT # 2 -- TRANSMISSION OIL
COOLER BYPASS VALVE
^ The recall # 281T Supplement Notification dated March, 1990 applied to specific 1989 and 1990
model year vehicles built through February 11, 1990. The service action is now being extended to
include those 1990 model year vehicles built from February 12, 1990 through the end of 1990
model year production.
As in the March, 1990 Supplement Notification, only those additional 1990 model year vehicles
operating in frigid climate regions are involved. Refer to the attached dealer notification letter for a
listing of the involved states.
^ Two new parts packages have been released for this recall. These new packages contain the oil
cooler hoses already assembled to the bypass valve. With the new valve and hose assemblies, it is
no longer necessary to cut the existing hoses to install the valve. Simply remove the existing
transmission-to-cooler hoses and install the new valve and hose assembly in their place.
The new parts packages, and the previous package (PN C3940361), are to be used for the
following applications:
- New package, PN C3940405, is to be used only for 1989 and 1990 AC and AY-B cars.
- New package, PN C3940406, is to be used only for 1990 AS-Body minivans/wagons.
- The previous package, PN C3940361, should continue to be used only for 1988 and 1989
AS-Body mini vans/wagons.
IMPORTANT:
^ Service procedures for the 1989 and 1990 cars and 1990 mini vans/wagons are included in this
dealer notification.
^ The service procedure for 1988 and 1989 mini vans/wagons remains the same as specified in the
December, 1989 Recall # 281T instructions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 211690
> Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing
Technical Service Bulletin # 211690 Date: 900604
A-604 A/T Oil Cooler - Flushing & Flow Testing
Models
1989-1990 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transaxle Oil Cooler Flushing And Flow Testing
Index
TRANSMISSION
Date
June 4, 1990
No.
21-16-90
(C21-10-0) P-1649 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
Discussion
The purpose of this bulletin is to emphasize the IMPORTANCE OF PROPERLY FLUSHING AND
FLOW TESTING THE TRANSAXLE OIL COOLER SYSTEM FOLLOWING ANY A-604 REPAIR
WHICH REQUIRES THE REMOVAL OR REPLACEMENT OF THE TRANSAXLE.
A clogged or restricted transaxle oil cooler system can be the cause of recurring transaxle failures.
Restriction of transaxle fluid flow through the oil cooler system can result in overheating of the fluid
and reduce lubrication flow to internal rotating parts.
Three types of transaxle oil cooler systems are used; oil to air, oil to engine coolant and a
combination oil to air and oil to engine coolant. When flushing a cooler system with a combination
of both, it will be necessary to flush each cooler separately. Vehicles equipped with the Bypass
valve, installed from Recall 281-T or Technical Service Bulletin 21- 28-89 must have the Bypass
valve cleaned separately.
This bulletin should be reviewed with all service personnel performing repairs to the A-604
transaxle.
NOTE: THERE ARE TWO DIFFERENT FLUSHING PROCEDURES FOR VEHICLES EQUIPPED
WITH THE DIFFERENT TYPE COOLER SYSTEMS. MAKE SURE YOU USE THE PROCEDURE
THAT APPLIES TO THE VEHICLE SYSTEM YOU ARE WORKING ON.
UNDER NO CIRCUMSTANCES SHOULD COMPRESSED AIR BE SUBSTITUTED FOR THE
FLUSHING PROCEDURE OUTLINED BELOW.
Tools and Material Required to Flush System
Hand suction gun. Mineral spirits. Shop air and blow gun. Gallon container ATF fluid.
Parts Required
Use only on vehicles equipped with pressure actuated bypass valve.
1 - Tie Strap PN 6016076
1 - Tie Strap PN 6016240
Flushing Procedure
FLUSHING PROCEDURE: FOR VEHICLES EQUIPPED WITH OIL TO AIR COOLER AND/OR
VEHICLES EQUIPPED WITH OIL TO
ENGINE COOLANT COOLER.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 211690
> Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing > Page 3871
Figure 1
1. Locate the inlet and outlet lines at the transaxle, Figure 1.
2. Disconnect both cooler lines at the transaxle.
3. Using a hand suction gun filled with mineral spirits, reverse flush the cooler by forcing mineral
spirits into the transaxle inlet hose while catching the fluid coming from the transaxle outlet line.
Observe for the presence of debris in the exiting fluid.
4. Repeat the flushing procedure until the exiting mineral spirits are clear and free of debris.
5. Use compressed air in intermittent spurts to blow out the remaining mineral spirits, again in the
reverse direction.
6. To remove any remaining mineral spirits, 1 Quart of ATF should be pumped through the cooler
system using the hand suction gun.
NOTE: IF AT ANY STAGE OF THE FLUSHING PROCESS, THE FLUIDS DO NOT FLOW
FREELY THROUGH THE SYSTEM, THE COOLER MUST BE REPLACED.
NOTE: IF THE VEHICLE IS EQUIPPED WITH A BYPASS VALVE, IT MUST BE REMOVED
FROM THE SYSTEM AND FLUSHED SEPARATELY. TO ASSURE THE VALVE IS
THOROUGHLY CLEANED, IT MUST BE REMOVED FROM THE H-FITTING ASSEMBLY. PAY
PARTICULAR ATTENTION TO THE WAY THE BYPASS VALVE WAS INSTALLED BEFORE
DISASSEMBLY, THE INLET SIDE OF THE BYPASS VALVE MUST BE CONNECTED TO THE
OUTLET LINE COMING FROM THE TRANSAXLE. SHOULD THERE BE ANY QUESTION OF
HOW TO REINSTALL THE BYPASS VALVE, REFER TO TSB 21-28-89.
7. Connect the cooler lines to the transaxle. Fill the transaxle to the proper level.
8. Complete the flow testing procedure outlined below.
Flushing Procedure For Trailer Tow Package
FLUSHING PROCEDURE: FOR VEHICLES EQUIPPED WITH TRAILER TOW PACKAGE,
INCLUDING A COMBINATION OF AN OIL TO
AIR COOLER AND OIL TO ENGINE COOLANT COOLER.
2. Locate the inlet and outlet cooler lines at the transmission, Figure 1.
2. Disconnect both cooler lines at the transmission.
3. Remove the hose connecting the two transmission oil coolers together.
4. Using a hand suction gun filled with mineral spirits, reverse flush the coolers separately by
forcing mineral spirits into the transaxle inlet hose while catching the fluid coming from the other
end of the cooler. Observe for the presence of debris in the exiting fluid.
5. Repeat the flushing procedure with each cooler until the exiting mineral spirits is clear and free of
debris.
6. Use compressed air in intermittent spurts to blow out the remaining mineral spirits, again in the
reverse direction.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 211690
> Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing > Page 3872
3. To remove any remaining mineral spirits, 1 Quart of ATF should be pumped through each cooler
using the hand suction gun.
NOTE: IF AT ANY STAGE OF THE FLUSHING PROCESS, THE FLUIDS DO NOT FLOW
FREELY THROUGH THE COOLER, IT WILL BE NECESSARY TO DETERMINE WHICH
COOLER(S) IS RESTRICTED AND REPLACE IT.
NOTE: IF THE VEHICLE IS EQUIPPED WITH A BYPASS VALVE, IT MUST BE REMOVED
FROM THE SYSTEM AND FLUSHED SEPARATELY. TO ASSURE THE VALVE IS
THOROUGHLY IT MUST BE REMOVED FROM THE H-FITTING ASSEMBLY. PAY PARTICULAR
ATTENTION TO THE WAY THE BYPASS VALVE WAS INSTALLED BEFORE DISASSEMBLY,
THE INLET SIDE OF THE BYPASS VALVE MUST BE CONNECTED TO THE OUTLET LINE
COMING FROM THE TRANSAXLE. SHOULD THERE BE ANY QUESTION OF HOW TO
REINSTALL THE BYPASS VALVE, REFER TO TSB 21-28-89.
8. Connect the cooler lines to the transaxle. Fill the transaxle to the proper level.
9. Complete the flow testing procedure outlined below.
Flow Testing Procedure
1. Disconnect the transaxle inlet cooler line at the transaxle, place the line in an empty gallon
container.
2. Shift the transaxle into neutral, start engine and run at curb idle for 20 seconds, while observing
the fluid flow. If the flow is intermittent or it takes longer than 20 seconds to collect one quart of
ATF, locate and replace the restricted cooler(s).
CAUTION: DO NOT FLOW MORE THAN ONE (1) QUART OF ATF OR INTERNAL DAMAGE
MAY OCCUR.
3. If fluid flow is within the acceptable limits, connect the transaxle cooler line to the transaxle and
fill it to the proper level.
Warranty and Labor Info.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No.
Reverse flush cooler system with
single cooler 21-33-41-55 0.5 Hrs.
Reverse flush cooler system with
dual coolers 21-33-41-57 0.7 Hrs.
optional bypass valve equipped 21-33-41-60 0.2 Hrs.
Cooler system flow check 21-33-40-56 0.4 Hrs.
FAILURE CODE: 38 - Fluid wrong/contaminated
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve
Technical Service Bulletin # 281T Date: 891201
Original TSB
No. 281T
December, 1989 To:
All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 281T Transmission Oil Cooler Bypass Valve
Models: 1988 and 1989 S-Body Models Equipped With Heavy Duty Trailer Tow Package -Plymouth Voyager and Grand Voyager, Dodge Caravan, Grand Caravan, Caravan C/V and Grand
Caravan C/V
The listed model vehicles equipped with the trailer tow package may experience restricted
transmission fluid flow through the oil cooler at low temperature (-15 degrees F and below). This
may result in lack of lubrication to the transmission and possible transmission failure.
To ensure adequate lubrication, a transmission oil cooler bypass valve system must be installed.
Important: Some of the involved vehicles may still be in dealer inventory. Be sure to complete the
service on these vehicles before delivery to customers.
Because of the cold weather nature of the condition, only those vehicles invoiced to dealers in the
Northern U.S. are included in this notification and service action. The following Zones are included:
Boston, Chicago, Denver, Detroit, Kansas City, Milwaukee, Minneapolis, Pittsburgh and Syracuse;
also the State of Alaska.
Parts distribution and Vehicle Lists will be limited to these dealers. However, vehicles in other
areas are eligible for the repair as needed to meet cold weather operation requirements upon
owner request.
Details of this service action are explained in the following sections. As an additional service aid, a
videotape demonstrating the service procedure is included in the December, 1989 Master Tech
program.
Vehicle, Parts, and Owner Info.
VEHICLE LIST
Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location)
will receive a listing of them with this letter, arranged in Vehicle Identification Number (VIN)
sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging
for service of involved vehicles.
Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of
this letter by Compak Mall for use in performing the service on involved vehicles upon request.
Parts
Parts packages, PN C3940361, are being shipped free of charge to all involved dealers for service
of affected vehicles. Each dealer to whom involved vehicles were invoiced (or the current dealer at
the same location) will receive enough parts packages to service 75% of those vehicles. Parts
(Continued)
Each recall parts package contains the following components:
Quantity Description
(1) Bypass valve
(2) Brass tees
(4) Nipple connectors
(4) Hose clamps
(1) Foam tube
(1) Tie strap
(1) Tie strap (with "push-in" retainer)
Also included in each package is an instruction summary for convenient reference by the servicing
technician.
Additional parts may be ordered without charge from Parts Depots if required. Order only as
needed for scheduled repairs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3877
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for the service with their dealers at the
earliest possible date. A copy of the owner notification letter is attached.
Enclosed with each owner notification is an Owner Recall Notification Form # 83- 295-0019. The
involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Service Procedure
Figure 1
Prior to performing this service, it is important to understand that the bypass valve, to function
properly, must be located and connected to the transmission oil cooler hoses in the correct oil flow
direction (Figure 1).
Figure 2
1. Using Chrysler Mopar Thread Sealant PN 4318034 or equivalent at all connections, assemble
the supplied bypass valve, tees and connectors as shown in Figure 2. Tighten the tees and
connectors to 12 N-m (110 in.lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3878
Figure 3
2. Raise vehicle on hoist for working access to the transmission oil cooler hoses routed along the
inboard side of the left front frame rail.
3. Measure 5-1/2 inches rearward from the front edge of the frame rail and 2 inches up from the
bottom of rail (Figure 3) and drill a 1/4 inch diameter hole in the rail.
Figure 4(3-Speed Transmission)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3879
Figure 5(4-Speed Transmission)
4. Referring to Figures 4 and 5, follow the cooler hoses routed from the transmission to clearly
identify the cooler "in" hose.
Figure 6
5. Place an oil pan under the vehicle to catch fluid leakage. (Oil loss will be minimal.)
6. Pushing the cooler hoses against the frame, cut the cooler "in" hose at the drilled hole (Figure 6)
and allow oil to drain.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3880
Figure 4(3-Speed Transmission)
Figure 5(4-Speed Transmission)
IMPORTANT: Illustration is typical of 4-speed hose routing. 3-speed hose routing differs; therefore
it is important to identify the cooler "in" and "out" hoses per Figures 4 and 5.
Figure 1
7. Slide 2 of the supplied clamps over the hose ends and install the cooler "in" end connectors of
the bypass valve assembly to the cut hose ends.
NOTE: Refer to Figure 1 to identify the male (pipe nipple) end of the valve. This end of the
assembly.must be connected to the cooler "in"
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3881
hose.
Figure 7(3-Speed Transmission Installation)
Figure 8(4-Speed Transmission Installation)
8. Cut the other hose (cooler "out") at the drilled hole, allow oil to drain, and connect the hose ends
to the valve assembly connectors in the
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3882
same manner.
9. Cut the supplied foam tube and wrap it around the bypass valve (Figures 7 and 8).
10. Tighten the supplied "push-in" tie strap around the foam tubing and cut off excess strap.
11. Engage the push-in tie strap in the drilled 1/4 inch hole (Figures 7 and 8).
NOTE: Because the hoses and hose routing differ on the 3-speed and 4- speed transmission, the
valve assembly must be positioned differently for each -- valve mounted vertically for the 4-speed
and at an angle for the 3- speed.
12. Tighten all hose clamps to 2 N-m (15 in.lbs).
13. Install the other supplied tie strap to secure the assembly to the frame rail (Figures 7 and 8).
Cut off excess strap.
14. Check and, if necessary, adjust transmission oil level.
Completion Information
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted by DIAL dealers on the DIAL
System. Non DIAL dealers may submit WROS. Claims submitted will be used by Chrysler to record
recall service completions and provide dealer payments.
Enter only one VIN per claim on a WRO. Fill in the labor operation number and time allowance and
write on the WRO "Customer Satisfaction Notification # 281T --Transmission Oil Cooler Bypass
Valve." Do not enter other service claims on the same WRO. Use the following labor operation
number and time allowance:
Labor Operation Time
Number Allowance
Install transmission oil cooler bypass valve. 21281282 0.5 Hour
Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall
claim processing instructions.
Parts Return
Not applicable.
Vehicle Not Available
If a vehicle is not available for this service for a known reason, let us know by filling outthe
pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe
the reason on a postcard and mall to:
Chrysler Motors 416-15-19 Recall Coordination P.O. Box 1919 Detroit, Michigan 48231-9986
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Customer Letter
CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE
Dear Chrysler Motors Vehicle Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a
free repair service to owners of certain 1988 and 1989 model vehicles equipped with the heavy
duty trailer tow package. Included are the Plymouth Voyager and Grand Voyager, Dodge Caravan,
Grand Caravan, Caravan C/V and Grand Caravan C/V. Your vehicle, whose Vehicle Identification
Number is shown on the enclosed form, is included in this offer. This service and the required parts
as described in this letter will be provided without charge.
The service is needed to prevent possible transmission damage in extremely cold weather resulting
from restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this
important service without delay.
To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply
to the transmission at all times. The work will take less than one hour to complete. However,
additional time may be required depending on how service appointments are scheduled and
processed. To arrange for this service:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3883
^ Contact your dealer as soon as possible to schedule an appointment for the free service.
^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and
give it to your dealer. The form identifies the vehicle and condition for which service is required.
If you have any problem obtaining the needed service, please contact the Chrysler
Zone Service Office in your area. (It is listed under "Service Assistance" in your Operator's
Manual.) A Zone representative will arrange for prompt servicing of your vehicle.
We regret any inconvenience that this action may cause you. However, we believe that this special
service will help to ensure your continuing satisfaction with your Voyager or Caravan.
Thank you for your attention to this important matter.
SERVICE AND PARTS OPERATIONS CHRYSLER MOTORS CORPORATION
Supplement # 1
No. 281T
March, 1990 SUPPLEMENT CUSTOMER SATISFACTION NOTIFICATION # 281 -TRANSMISSION OIL COOLER BYPASS VALVE: THIS PROGRAM HAS BEEN EXTENDED TO
INCLUDE ADDITIONAL VEHICLES IN SPECIFIED FRIGID CLIMATE STATES To:
All Dodge and Chrysler-Plymouth Dealers in Involved Zones; All Regional and Zone Service and
Parts Managers
Subject: Customer Satisfaction Notification # 281T -- Transmission Oil Cooler Bypass Valve -Additional Vehicles in Specified States
Models: The Following Additional Models Equipped With the A604 4-Speed Automatic
Transmission and External Transmission Oil-To-Air Cooler:
^ 1989 AC-Body Cars -- Chrysler New Yorker, New Yorker Landau and Dodge Dynasty
^ 1989 AS-Body Models Without Heavy Duty Trailer Tow Package - - Voyager, Grand Voyager,
Caravan, Grand Caravan, Caravan CN Van and Extended Van
^ 1990 AC & AY-Body Cars -- Chrysler Salon, New Yorker Landau, New Yorker Fifth Avenue,
Imperial and Dodge Dynasty
^ 1990 AS-Body Models Equipped With Heavy Duty Trailer Tow Package -- Voyager, Grand
Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended Van
^ 1990 AS Body Chrysler Town & Country
Location: This Service Action Applies Only to Vehicles in the Following Frigid Climate States:
^ Minneapolis Zone -- Minnesota, North Dakota, South Dakota
^ Milwaukee Zone -- Wisconsin, Michigan (U.P.)
^ Detroit Zone -- Michigan
^ Denver Zone -- Montana, Wyoming
^ Portland Zone -- Alaska
Reference: Dealer notification letter # 281T, December, 1989, for 1988-9 AS-Body vehicles with
heavy duty trailer tow package and located in Northern U.S.
The initial notification for recall # 281T involved 1988 and 1989 model year AS-Body vehicles
equipped with trailer tow and operating in cold climates. The action was taken to eliminate the
potential for transmission damage due to oil flow restriction through the oil cooler during cold
weather.
The recall population is now being expanded to also include certain additional 4- speed
transmission equipped AS, AC and AY-Body vehicles with external transmission oil-to-air coolers
operating in frigid climate regions. Note:
Vehicles already equipped with oil cooler bypass valve systems under Technical Service Bulletin #
21-28-89 do not require further service for this condition.
All service requirements for the additional vehicles are the same as for the original Recall # 281T
except as noted in the following sections. A copy of the original dealer notification letter of
December, 1989 is enclosed for your reference.
Parts
The same parts package used for previously involved vehicles, PN C3940361, is required for the
added models. Parts sufficient to repair 75% of the involved vehicles will be shipped free of charge
to involved dealers as supplies become available.
Note: For 1990 AS-Body models only, an additional bracket, PN C3940385, is require to complete
the recall package installation. Six of these
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3884
brackets will be provided free of charge to involved dealers for use as required. Additional brackets,
if needed, are available for ordering from the parts depot.
Owner Notification and Service Scheduling
Owners will be notified of the service requirement aftershipment of the recall parts to involved
dealers.
Service Procedure
^ The procedure for installing the bypass valve assembly on 1989 AS-Body models without trailer
tow is the same as shown in the instructions already provided in the dealer recall notification letter
(# 281T) for trailer tow vehicles.
^ For 1989 AC-Body models, the procedure is the same as previously described for recall # 281T
except there is no drilling required (procedure step 3). A 1/4 inch hole already exists in the frame
rail for the push-in tie strap to retain the valve assembly.
^ The procedure for 1990 AC and AY-Body models is also the same as previously described for
recall # 281T except as follows:
FIGURE 11990 AC AND AY-BODY CARS
- A plate is attached to the frame rail where the valve assembly is to be located. Therefore, a 1/4
inch hole must be drilled through the plate (at the location shown in Figure 1 of this letter to
accommodate the pushin tie strap.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3885
FIGURE 21990 AC AND AY-BODY CARS
- Install the other retaining tie strap by routing the strap through the two existing frame holes as
shown in Figure 2.
Figure 31990 AS-Body with External Cooler (Trailer Tow or Town & Country)
^ Installation of the bypass valve assembly on 1990 AS-Body models differs as follows (see Figure
3):
- To install the valve assembly, cut the cooler hoses in line with the center of the large hole in the
bottom of the frame.
- Install bracket PN C3940385 to retain the upper cooler hose, using the existing lower battery tray
attaching bolt.
- Since the valve assembly will be clear of the frame rail with this installation, the anti-rattle foam
tube and tie straps are not required.
Important: Remember that the bypass valve must be installed in the proper flow direction. Be sure
to identify the transmission fluid out (outlet and in (inlet) fittings at the transmission as shown in
Figure 5 of the original Recall # 281T service procedure. Then follow the hoses from the
transmission to the valve mounting location to ensure that the valve is attached properly to the "in"
and "out" hoses as shown in Figure 8 of the original recall service procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3886
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE
Dear Chrysler Corporation Vehicle Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a
free service at this time to owners of certain 1989 and 1990 model vehicles equipped with 4-speed
automatic transmissions. The vehicle whose Vehicle Identification Number is shown on the
enclosed form is included in this offer. The service and requiredpartsas describedin this letter will
be provided to you without charge.
This service will prevent possible transmission damage in extremely cold weather resulting from
restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this
important service without delay.
To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply
to the transmission at all times. If your vehicle has already had this service performed, please
disregard this notice. Otherwise, to obtain this service:
^ Contact your dealer promptly to schedule an appointment for the free service.
^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and
give it to your dealer. The form identifies the vehicle and condition for which service is required.
The work will take less than one hour to complete. However, additional time may be required
depending on how service appointments are scheduled and processed.
If you have any problem obtaining the needed service, please contact the Chrysler Zone Service
Office in your area. (it is listed under "Service Assistance" in your Operator's Manual.) A Zone
representative will arrange for prompt servicing of your vehicle.
We regret any inconvenience that this action may cause you. However, we believe that this special
service will help to ensure your continuing satisfaction with your Chrysler product.
Thank you for your attention to this important matter.
Supplement # 2
NO. 281T
October, 1990 SUPPLEMENT # 2 CUSTOMER SATISFACTION NOTIFICATION # 281T -TRANSMISSION OIL COOLER BYPASS VALVE: THIS PROGRAM HAS BEEN EXTENDED TO
INCLUDE ADDITIONAL 1990 MODEL YEAR VEHICLES IN SPECIFIED FRIGID CLIMATE
STATES AND TO REVISE PARTS AND PROCEDURES FOR SPECIFIED MODELS To:
All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 281T -- Transmission Oil Cooler Bypass Valve -Additional 1990 Vehicles in Specified States and Revised Parts/Procedures
Models: All Following Vehicles Equipped With A604 4-Speed Automatic Transmission and Locate
in States Specified Below:
^ 1989 AC -- Chrysler New Yorker, New Yorker Landau and Dodge Dynasty
^ 1990 AC & AY -- Chrysler Salon, New Yorker Landau, New Yorker Fifth Avenue, Imperial and
Dodge Dynasty
^ 1990 AS -- Voyager, Grand Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended
Van -- Equipped With Heavy Duty Trailer Tow Package
^ 1990 AS -- Chrysler Town & Country -- All
Location: This Service Action Applies Only to Vehicles in the Following Frigid Climate States:
^ Minneapolis Zone -- Minnesota, North Dakota, South Dakota
^ Milwaukee Zone -- Wisconsin, Michigan (U.P.)
^ Detroit Zone -- Michigan
^ Denver Zone -- Montana, Wyoming
^ Portland Zone -- Alaska
Reference: ^ Dealer notification letter # 281T, December, 1989. ^
Dealer notification letter # 281T supplement, March, 1990.
The Recall # 281T Supplement dated March, 1990 applied to specific 1989 and 1990 model year
vehicles built throu h February 11, 1990 and located in frigid climate states. The service action is
nowleing extended to include 1990 model year vehicles in the same states which were built from
February 12, 1990 through the end of 1990 model year production.
Important: Some of the involved vehicles may still be in dealer stock. Be sure to complete the
service on these vehicles before retail delivery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3887
Revised parts packages have been developed for 1989 and 1990 model year AC/AYBody cars and
for 1990 AS-Body minivans and wagons. These packages contain preassembled bypass valve and
oil cooler hose components. All 1988 and 1989 AS-Body vehicles will continue to use the previous
parts package. Details of this service action are explained in the following sections.
Note: Vehicles already equipped with oil cooler bypass valve systems under Technical Service
Bulletin # 21-28-89 or previously serviced for this recall with the original parts package do not
require further service for this condition.
Vehicle List
Each dealer to whom additional later-built 1990 model year vehicles were invoiced (or the current
dealer at the same location) will receive a vehicle list with this letter arranged in Vehicle
Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for
dealer reference in arranging for service of involved vehicles.
Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of
this letter by Compak Mail for use in performing the service on involved vehicles upon request.
Parts
Parts packages are being distributed free of charge to all involved dealers for service of affected
vehicles. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same
location) will receive enough parts packages to service 50% of those vehicles.
Two new parts packages have been released for specific models as follows: Included in each
package is an instruction summary for convenient reference by the servicing technician.
Note: For 1988 and 1989 AS-Body vehicles involved in the original Recall # 281T notification of
December, 1989, and the Recall # 281T Supplement of March, 1990, continue to use the original
parts package, PN C3940361.
Additional parts may be ordered without charge from Parts Depots if required. Order only as
needed for scheduled repairs.
Owner Notification and Service Scheduling
All involved owners of additional 1990 vehicles who are known to Chrysler are being notified of the
service requirement by first class mail. They are requested to schedule appointments for the
service with their dealers at the earliest possible date. A copy of the owner notification letter is
attached.
Enclosed with each owner notification is an Owner Recall Notification Form # 83-295-0019. The
involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Service Procedure
A. 1989 and 1990 AC/AY-Body Passenger Cars
1. Place an oil pan under the vehicle to catch fluid leakage (oil loss will be minimal).
2. Disconnect the existing cooler hoses from the fittings at the transmission and at the external oil
cooler mounted at the front of the radiator. Save the clamps for reinstallation.
3. Install the supplied valve and hose assembly (PN C3940405) in place of the removed hoses as
follows.
Note: The hoses on the new assembly are banded together with tape and the ends are pre-molded
to align them for installation to the appropriate transmission and cooler fittings. Do not disturb the
tape wrappings.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3888
Figure 1
Vehicles not equipped with Bendix Anti-Lock Brake System -Install the supplied bracket on the valve (with the bracket mounting holes toward the front as shown
in Figure 1). Loosely attach the bracket to the left front frame rail with the supplied screw, using the
existing hole in the rail.
Figure 2
Figure 3
^ Vehicles equipped with Bendix Anti-Lock Brake System (ABS) -There is an existing cooler line clip at the ABS controller module mounted to the left front frame rail
(Figure 2). Use this existing clip to support the valve and hose assembly as shown in Figure 3.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3889
Figure 4
Figure 5
^ All Vehicles -- Attach the hoses to the fittinqs at the external oil cooler (Figure 4) and at the
transmission (Figure 5). Secure with the original clamps.
^ Tighten the valve support bracket screw (non ABS cars) or clip screw (Bendix ABS equipped
cars).
^ Start the engine and check for leaks.
^ Check and, if necessary, adjust the transmission oil level.
Figure 2
Figure 3
B. 1990 AS-Body Mini Vans/Wagons With Heavy Duty Trailer Tow
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3890
1. Place an oil pan under the vehicle to catch fluid leakage (oil loss will be minimal).
2. Disconnect the existing cooler hoses from the fittings at the base of the radiator (Figure 2) and
from the transmission fittings (Figure 3). Save the clamps for reinstallation.
3. Install the supplied valve, hose and bracket assembly (PN C3940406) in place of the removed
hoses as follows.
Note: The hoses on the new assembly are banded together with tape and the ends are pre-molded
to align them for installation to the appropriate transmission and cooler fittings. Do not disturb the
tape wrappings.
Figure 1
^ Support the valve and hose assembly by loosely attaching the valve support bracket to the left
front frame rail with the supplied screw, using the existing hole in the rail (Figure 1).
Figure 2
^ Attach the hoses to the fittings at the base of the radiator and secure with the original clamps
(Figure 2).
Important: Note that bolh hoses do not attach to the lower radiator tank fittings. As shown in Figure
2, one hose attaches to the lower radiator tank fitting and the other hose attaches to the external
cooler tube.
Figure 3
^ ^ Attach the hoses to the transmission fittings and secure with the original clamps (Figure 3).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3891
^ ^ Tighten the valve support bracket screw.
^ ^ Start engine and check for leaks.
^ ^ Check and, if necessary, adjust the transmission oil level.
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record recall service completions and provide dealer
payments. Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
^ Install transmission oil cooler 21281282 0.5 Hour bypass valve -- 1990 AS-Body with heavy duty
trailer tow.
Note: This is the same labor operation number and time allowance as specified for vehicles
involved in the original recall # 281T notification of December, 1989.
^ Install transmission oil cooler 21281283 0.3 Hour bypass valve -- 1989 and 1990 AC/AY-Body
cars
Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H, for complete recall
claim processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for this service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe
the reason on a postcard and mail to:
Chrysler Corporation 416-15-19 Recall Coordination P.O. Box 1919 Detroit, Michigan 48231-9986
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE
Dear Chrysler Motors Vehicle Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a
free service at this time to owners of certain 1990 model vehicles equipped with 4-speed automatic
transmissions. The vehicle whose Vehicle Identification Number is shown on the enclosed form is
included in this offer. The service and required parts as described in this letter will be provided to
you without charge.
This service will prevent possible transmission damage in extremely cold weather resulting from
restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this
important service without delay.
To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply
to the transmission at all times. If your vehicle has already had this service performed, please
disregard this notice. Otherwise, to obtain this service:
^ Contact your dealer promptly to schedule an appointment for the free service.
^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and
give it to your dealer. The form identifies the vehicle and condition for which service is required.
The work will take less than one hour to complete. However, additional time may be required
depending on how service appointments are scheduled and processed.
If you have any problem obtaining the needed service, please contact the Chrysler Zone Service
Office in your area. (It is listed under "Service Assistance" in your Operator's Manual.) A Zone
representative will arrange for prompt servicing of your vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T >
Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3892
We regret any inconvenience that this action may cause you. However, we believe that this special
service will help to ensure your continuing satisfaction with your Chrysler product.
Thank you for your attention to this important matter.
Dealer Instructions
IMPORTANT
DEALER INSTRUCTIONS
CUSTOMER SATISFACTION NOTIFICATION # 281T, SUPPLEMENT # 2 -- TRANSMISSION OIL
COOLER BYPASS VALVE
^ The recall # 281T Supplement Notification dated March, 1990 applied to specific 1989 and 1990
model year vehicles built through February 11, 1990. The service action is now being extended to
include those 1990 model year vehicles built from February 12, 1990 through the end of 1990
model year production.
As in the March, 1990 Supplement Notification, only those additional 1990 model year vehicles
operating in frigid climate regions are involved. Refer to the attached dealer notification letter for a
listing of the involved states.
^ Two new parts packages have been released for this recall. These new packages contain the oil
cooler hoses already assembled to the bypass valve. With the new valve and hose assemblies, it is
no longer necessary to cut the existing hoses to install the valve. Simply remove the existing
transmission-to-cooler hoses and install the new valve and hose assembly in their place.
The new parts packages, and the previous package (PN C3940361), are to be used for the
following applications:
- New package, PN C3940405, is to be used only for 1989 and 1990 AC and AY-B cars.
- New package, PN C3940406, is to be used only for 1990 AS-Body minivans/wagons.
- The previous package, PN C3940361, should continue to be used only for 1988 and 1989
AS-Body mini vans/wagons.
IMPORTANT:
^ Service procedures for the 1989 and 1990 cars and 1990 mini vans/wagons are included in this
dealer notification.
^ The service procedure for 1988 and 1989 mini vans/wagons remains the same as specified in the
December, 1989 Recall # 281T instructions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 211690 >
Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing
Technical Service Bulletin # 211690 Date: 900604
A-604 A/T Oil Cooler - Flushing & Flow Testing
Models
1989-1990 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transaxle Oil Cooler Flushing And Flow Testing
Index
TRANSMISSION
Date
June 4, 1990
No.
21-16-90
(C21-10-0) P-1649 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
Discussion
The purpose of this bulletin is to emphasize the IMPORTANCE OF PROPERLY FLUSHING AND
FLOW TESTING THE TRANSAXLE OIL COOLER SYSTEM FOLLOWING ANY A-604 REPAIR
WHICH REQUIRES THE REMOVAL OR REPLACEMENT OF THE TRANSAXLE.
A clogged or restricted transaxle oil cooler system can be the cause of recurring transaxle failures.
Restriction of transaxle fluid flow through the oil cooler system can result in overheating of the fluid
and reduce lubrication flow to internal rotating parts.
Three types of transaxle oil cooler systems are used; oil to air, oil to engine coolant and a
combination oil to air and oil to engine coolant. When flushing a cooler system with a combination
of both, it will be necessary to flush each cooler separately. Vehicles equipped with the Bypass
valve, installed from Recall 281-T or Technical Service Bulletin 21- 28-89 must have the Bypass
valve cleaned separately.
This bulletin should be reviewed with all service personnel performing repairs to the A-604
transaxle.
NOTE: THERE ARE TWO DIFFERENT FLUSHING PROCEDURES FOR VEHICLES EQUIPPED
WITH THE DIFFERENT TYPE COOLER SYSTEMS. MAKE SURE YOU USE THE PROCEDURE
THAT APPLIES TO THE VEHICLE SYSTEM YOU ARE WORKING ON.
UNDER NO CIRCUMSTANCES SHOULD COMPRESSED AIR BE SUBSTITUTED FOR THE
FLUSHING PROCEDURE OUTLINED BELOW.
Tools and Material Required to Flush System
Hand suction gun. Mineral spirits. Shop air and blow gun. Gallon container ATF fluid.
Parts Required
Use only on vehicles equipped with pressure actuated bypass valve.
1 - Tie Strap PN 6016076
1 - Tie Strap PN 6016240
Flushing Procedure
FLUSHING PROCEDURE: FOR VEHICLES EQUIPPED WITH OIL TO AIR COOLER AND/OR
VEHICLES EQUIPPED WITH OIL TO
ENGINE COOLANT COOLER.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 211690 >
Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing > Page 3898
Figure 1
1. Locate the inlet and outlet lines at the transaxle, Figure 1.
2. Disconnect both cooler lines at the transaxle.
3. Using a hand suction gun filled with mineral spirits, reverse flush the cooler by forcing mineral
spirits into the transaxle inlet hose while catching the fluid coming from the transaxle outlet line.
Observe for the presence of debris in the exiting fluid.
4. Repeat the flushing procedure until the exiting mineral spirits are clear and free of debris.
5. Use compressed air in intermittent spurts to blow out the remaining mineral spirits, again in the
reverse direction.
6. To remove any remaining mineral spirits, 1 Quart of ATF should be pumped through the cooler
system using the hand suction gun.
NOTE: IF AT ANY STAGE OF THE FLUSHING PROCESS, THE FLUIDS DO NOT FLOW
FREELY THROUGH THE SYSTEM, THE COOLER MUST BE REPLACED.
NOTE: IF THE VEHICLE IS EQUIPPED WITH A BYPASS VALVE, IT MUST BE REMOVED
FROM THE SYSTEM AND FLUSHED SEPARATELY. TO ASSURE THE VALVE IS
THOROUGHLY CLEANED, IT MUST BE REMOVED FROM THE H-FITTING ASSEMBLY. PAY
PARTICULAR ATTENTION TO THE WAY THE BYPASS VALVE WAS INSTALLED BEFORE
DISASSEMBLY, THE INLET SIDE OF THE BYPASS VALVE MUST BE CONNECTED TO THE
OUTLET LINE COMING FROM THE TRANSAXLE. SHOULD THERE BE ANY QUESTION OF
HOW TO REINSTALL THE BYPASS VALVE, REFER TO TSB 21-28-89.
7. Connect the cooler lines to the transaxle. Fill the transaxle to the proper level.
8. Complete the flow testing procedure outlined below.
Flushing Procedure For Trailer Tow Package
FLUSHING PROCEDURE: FOR VEHICLES EQUIPPED WITH TRAILER TOW PACKAGE,
INCLUDING A COMBINATION OF AN OIL TO
AIR COOLER AND OIL TO ENGINE COOLANT COOLER.
2. Locate the inlet and outlet cooler lines at the transmission, Figure 1.
2. Disconnect both cooler lines at the transmission.
3. Remove the hose connecting the two transmission oil coolers together.
4. Using a hand suction gun filled with mineral spirits, reverse flush the coolers separately by
forcing mineral spirits into the transaxle inlet hose while catching the fluid coming from the other
end of the cooler. Observe for the presence of debris in the exiting fluid.
5. Repeat the flushing procedure with each cooler until the exiting mineral spirits is clear and free of
debris.
6. Use compressed air in intermittent spurts to blow out the remaining mineral spirits, again in the
reverse direction.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 211690 >
Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing > Page 3899
3. To remove any remaining mineral spirits, 1 Quart of ATF should be pumped through each cooler
using the hand suction gun.
NOTE: IF AT ANY STAGE OF THE FLUSHING PROCESS, THE FLUIDS DO NOT FLOW
FREELY THROUGH THE COOLER, IT WILL BE NECESSARY TO DETERMINE WHICH
COOLER(S) IS RESTRICTED AND REPLACE IT.
NOTE: IF THE VEHICLE IS EQUIPPED WITH A BYPASS VALVE, IT MUST BE REMOVED
FROM THE SYSTEM AND FLUSHED SEPARATELY. TO ASSURE THE VALVE IS
THOROUGHLY IT MUST BE REMOVED FROM THE H-FITTING ASSEMBLY. PAY PARTICULAR
ATTENTION TO THE WAY THE BYPASS VALVE WAS INSTALLED BEFORE DISASSEMBLY,
THE INLET SIDE OF THE BYPASS VALVE MUST BE CONNECTED TO THE OUTLET LINE
COMING FROM THE TRANSAXLE. SHOULD THERE BE ANY QUESTION OF HOW TO
REINSTALL THE BYPASS VALVE, REFER TO TSB 21-28-89.
8. Connect the cooler lines to the transaxle. Fill the transaxle to the proper level.
9. Complete the flow testing procedure outlined below.
Flow Testing Procedure
1. Disconnect the transaxle inlet cooler line at the transaxle, place the line in an empty gallon
container.
2. Shift the transaxle into neutral, start engine and run at curb idle for 20 seconds, while observing
the fluid flow. If the flow is intermittent or it takes longer than 20 seconds to collect one quart of
ATF, locate and replace the restricted cooler(s).
CAUTION: DO NOT FLOW MORE THAN ONE (1) QUART OF ATF OR INTERNAL DAMAGE
MAY OCCUR.
3. If fluid flow is within the acceptable limits, connect the transaxle cooler line to the transaxle and
fill it to the proper level.
Warranty and Labor Info.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No.
Reverse flush cooler system with
single cooler 21-33-41-55 0.5 Hrs.
Reverse flush cooler system with
dual coolers 21-33-41-57 0.7 Hrs.
optional bypass valve equipped 21-33-41-60 0.2 Hrs.
Cooler system flow check 21-33-40-56 0.4 Hrs.
FAILURE CODE: 38 - Fluid wrong/contaminated
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the
transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Relay, A/T > Component Information > Locations > Component Locations
Transmission Position Relay: Component Locations
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Relay, A/T > Component Information > Locations > Component Locations > Page 3907
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3916
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3917
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3918
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page
3924
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page
3925
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3930
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3931
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3932
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3938
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3939
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
3942
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
3943
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
3944
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 3947
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 3950
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3953
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3954
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3955
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Locations
41 TE/AE Transaxle Pressure And Cooler Ports
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3967
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3972
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3973
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3974
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3980
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3985
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3986
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3987
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Page 3988
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor
Transmission Speed Sensor: Description and Operation Output Speed Sensor
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor > Page 3991
Transmission Speed Sensor: Description and Operation Turbine Speed Sensor
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque
convertor turbine).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Description and Operation > Page 3992
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Description and Operation
Transmission Temperature Sensor/Switch: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4004
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4005
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4006
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4012
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4013
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4014
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4015
A604 (41TE) 4 Speed Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information
Valve Body: Description and Operation General Information
The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle
clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil
pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a
positive displacement, gear and crescent type pump. It is driven by the engine through the torque
converter hub.
The valve body has two major functions:
- Control line pressure and TCC pressure
- Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of
the manual and switch valves
Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the
pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator
valve. The valve body uses five valves along with four solenoids in the solenoid assembly to
provide control of the transaxle through all of its gear ranges. They perform all functions needed to
operate the transaxle for each of its gear ranges.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 4018
Valve Body: Description and Operation Manual Valve
The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the
appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions.
The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the
middle position in both Park and Neutral. The valve moves to the right position when Reverse is
selected.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 4019
Valve Body: Description and Operation Regulator Valve
The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The
pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits,
pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a
spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure.
Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve
pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring
tension working against oil pressure to keep or maintain the oil at specific pressures.
Regulated.pressure varies depending on the gear range the transaxle is operating in.
A system of sleeves and ports allows the regulator valve to work at one of three different
predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the
intake side of the oil pump.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 4020
Valve Body: Description and Operation Solenoid Pack
DESCRIPTION
This is an electrical assembly that has an 8-way connector. It contains four electro-magnetic
solenoids that are used to control (under the direction of the controller) the hydraulic circuits within
the transaxle. Also inside are three switches that are used to sense when hydraulic pressure is
present in various circuits.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 4021
Valve Body: Description and Operation
General Information
The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle
clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil
pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a
positive displacement, gear and crescent type pump. It is driven by the engine through the torque
converter hub.
The valve body has two major functions:
- Control line pressure and TCC pressure
- Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of
the manual and switch valves
Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the
pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator
valve. The valve body uses five valves along with four solenoids in the solenoid assembly to
provide control of the transaxle through all of its gear ranges. They perform all functions needed to
operate the transaxle for each of its gear ranges.
Manual Valve
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 4022
The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the
appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions.
The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the
middle position in both Park and Neutral. The valve moves to the right position when Reverse is
selected.
Regulator Valve
The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The
pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits,
pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a
spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure.
Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve
pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring
tension working against oil pressure to keep or maintain the oil at specific pressures.
Regulated.pressure varies depending on the gear range the transaxle is operating in.
A system of sleeves and ports allows the regulator valve to work at one of three different
predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the
intake side of the oil pump.
Solenoid Pack
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 4023
DESCRIPTION
This is an electrical assembly that has an 8-way connector. It contains four electro-magnetic
solenoids that are used to control (under the direction of the controller) the hydraulic circuits within
the transaxle. Also inside are three switches that are used to sense when hydraulic pressure is
present in various circuits.
Solenoid Switch Valve
The solenoid switch valve controls the direction of line pressure from the LR/CC solenoid. When
the valve is shifted to the right, it allows the low/reverse clutch to be pressurized. When it is shifted
to the left, it directs line pressure to the TC and CC control valves to operate the TC clutch. The
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 4024
valve is shifted to the right in all positions except 2nd, 3rd and 4th gear. When the transaxle
upshifts to 2nd gear, the valve moves to the left, which allows converter clutch engagement when
needed. The valve must return to the right before a downshift to 1st gear can occur.
Torque Converter Clutch Control Valve
The Torque Converter Clutch (TCC) control valve controls the back (ON) side of the torque
converter clutch. When the TCM energizes the LR/CC solenoid to engage the converter clutch
piston, the TCC control valve and torque converter control valves move to the left. The oil on the
front (OFF) side of the converter clutch piston is vented to the sump.
Line pressure enters the TCC control valve through the manual valve, and then passes through the
TCC control valve and the torque converter control valve to the back (ON) side of the converter
clutch piston. Line pressure forces the piston forward, which engages the torque converter clutch.
This action effectively connects the torque converter turbine with the impeller. Line pressure also
flows from the regulator valve, through the torque converter control valve, to the cooler and cooler
bypass, for improved fluid and transaxle cooling.
Torque Converter Control Valve
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 4025
The torque converter control valves main responsibility is to control. hydraulic pressure applied to
the front (OFF) side of the converter clutch. Line pressure from the regulator valve is fed to the
torque converter control valve, where it passes through the valve. The torque converter control
valve reduces, or regulates, the pressure slightly. The torque converter control valve pressure is
then directed to the converter clutch control valve and to the front side of the converter clutch
piston. The pressure that is being fed to the front of the piston pushes the piston back. This
disengages the converter clutch. The oil then passes around the outside of the piston, flowing out
of the torque converter and back to the torque converter control valve. From the torque converter
control valve, the oil flows to the transaxle oil cooler and cooler bypass valve. It returns to the
transaxle as lube oil pressure.
Beginning in 1996, the torque converter control valve was modified to delete the function of
regulating the flow to the torque converter when the converter clutch is not applied. The valve
switches the direction of fluid flow when the converter clutch is applied and vents the release side
of the torque converter clutch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation
Valve Body: Service and Repair Removal and Installation
3 Speed Automatic Transmission
VALVE BODY RECONDITION
NOTE: Prior to removing any transaxle subassemblies, plug all openings and thoroughly clean
exterior of the unit, preferably by steam. Cleanliness through entire disassembly and assembly
cannot be overemphasized. When disassembling, each part should be washed in a suitable
solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in
the transaxles are accurately machined; therefore, careful handling of all parts must be exercised
to avoid nicks or burrs. Remove all old R.T.V. sealant before applying new R.T.V. sealant. Use only
R.T.V. sealant when installing oil pan.
1. Remove or install neutral starting and back-up lamp switch.
Oil Pan Bolts
Oil Pan
Oil Filter Screws
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4028
Oil Filter
Parking Rod E-Clip
Parking Rod
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4029
Valve Body Attaching Bolts
Valve Body And Governor Tubes
CAUTION: Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of
the aluminum body or transfer plate will result in sticking valves, excessive leakage, or both. When
removing or installing valves or plugs, slide them in or out carefully. Do not use force.
Detent Spring Attaching Screw And Spring
WARNING: Tag all springs as they are removed for reassembly identification.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4030
Valve Body Screws
Valve Body Screws
Transfer Plate And Separator Plate
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4031
Steel Ball Locations
Throttle Shaft E-Clip
E-Clip, Washer And Oil Seal
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4032
Manual Valve Lever And Assembly
Throttle Valve Lever And Assembly
Manual Valve
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4033
Pressure Regulator And Adjusting Screw Bracket
Pressure Regulators And Manual Controls
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4034
Governor Plugs
Pressure Regulator Valve Plugs
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4035
Shift And Shuttle Valves
CLEANING AND INSPECTION
1. Allow all parts to soak a few minutes in a suitable clean solvent. Wash thoroughly and blow dry
with compressed air. Make sure all passages are
clean and free from obstructions.
2. Inspect manual and throttle valve operating levers and shafts for being bent, worn or loose. If a
lever is loose on its shaft, it should be replaced. Do
not attempt to straighten bent levers.
3. Inspect all mating surfaces for burrs, nicks and scratches. Minor blemishes may be removed with
crocus cloth, using only a very light pressure.
Using a straightedge, inspect all mating surfaces for warpage or distortion. Slight distortion may be
corrected, using a surface plate. Make sure all metering holes in steel plate are open. Using a pen
light, inspect bores in valve body for scores scratches, pits and irregularities.
4. Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs,
nicks, and scores. Small nicks and scores may be
removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The
sharpness of these edges is vitally important because it prevents foreign matter from lodging
between valve and valve body, thus reducing possibility of sticking. Inspect all valves and plugs for
freedom of operation in valve body bores.
5. When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the
bores. The valve body bores do not change
dimensionally with use. Therefore, a valve body that was functioning properly when vehicle was
new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace
valve body unless it is damaged in handling.
6. Installation is the reverse of removal. Tighten all valve body screws to 5 Nm (40 in.lbs.). Fill
transaxle to the proper level with ATF.
4 Speed Automatic Transmission
Removal
Oil Pan Bolts
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4036
Oil Pan
Oil Filter
Valve Body Attaching Bolts
NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4037
Push Park Rollers From Guide Bracket
Remove Valve Body
Valve Body Removed
Installation
To install valve body, reverse removal procedure.
CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve
body is mishandled or dropped.
NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise.
Guide park rod rollers into guide bracket, while shifting manual lever assembly out of the
installation position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4038
Valve Body: Service and Repair Solenoid Assembly Replacement
REMOVAL
Input Speed Sensor Removed
Remove Sound Cover
Remove Attaching Screws
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4039
Remove Solenoid Assembly
INSTALLATION
To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4040
Valve Body: Service and Repair 41TE 4-Speed
Transmission Range Sensor Screw
Transmission Range Sensor Removed
Manual Shaft And Rooster Comb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4041
2-4 Accumulator Plate
TRS, Manual Shaft, And 2-4 Accumulator
Valve Body Screws
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4042
Valve Body And Transfer Plate
Transfer Plate And Separator Plate
Ball Check Location
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 4043
Springs And Valves Location
Remove Or Install Dual Retainer Plate
TC Limit Valve And Low/Reverse Switch Valve
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing
and Inspection
Clutch Switch: Testing and Inspection
Clutch (Inhibitor) Switch Test
1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end
of switch terminal.
2. Connect a test light to remaining terminal end and ground.
3. Test light should be on when pedal is in normal position and off when pedal is depressed.
4. If above step is not as specified, replace clutch switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information >
Technical Service Bulletins > Clutch Splines & Pilot Bushing - Lubrication
Pilot Bearing: Technical Service Bulletins Clutch Splines & Pilot Bushing - Lubrication
Models
AA, AB, AD, AG, AH, AJ, AK, AL, AN, AP, AQ, AS Bodies Through 1989
Subject
Clutch Splines/Pilot Bushing Lubrication
Index
CLUTCH
Date
January 16, 1989
No.
06-01-89
P-0046 (C06-01-9) BODY CODE LEGEND
AA - Spirit/Acclaim AB - Dodge Ram Van/Wagon
AD - Dodge Ram Pickup/Ram Charger AG - Daytona
AH - LeBaron/LeBaron GTS AJ - LeBaron
AK - Aries/Reliant AL - Omni/Horizon
AN - Dodge Dakota/Dakota Sport AP - Shadow/Sundance
AQ - Chrysler TC AS - Caravan/Voyager
This Technical Service Bulletin supersedes ALL previous Service Technical Publications through
1989 covering the lubrication of the clutch splines and pilot bushing. The procedures outlined in this
bulletin apply to all domestic cars and trucks equipped with manual transmissions and transaxles.
SERVICE PROCEDURE
NOTE: THIS PROCEDURE SHOULD BE PERFORMED ANYTIME THE
TRANSMISSION/TRANSAXLE IS REMOVED FROM THE ENGINE AND/OR CLUTCH SERVICE
IS PERFORMED.
CLUTCH SPLINES
1. Thoroughly clean the input shaft clutch splines and clutch disc splines, they must be free of any
dirt or rust.
2. Apply a light coat of wheel bearing grease PN 4318064 evenly to the entire length of the
exposed input shaft splines. Be sure all excessive lubricant is removed.
NOTE: THE USE OF ALTERNATIVE OIL BASED LUBRICANTS IS NOT RECOMMENDED AS
THESE LUBRICANTS WILL EVENTUALLY DRY UP OR BURN OFF LEAVING ONLY A DRY
RESIDUE.
REAR WHEEL DRIVE VEHICLES - PILOT BUSHING
1. Thoroughly clean the pilot bearing journal at the end of the input shaft and the inside of the pilot
bushing.
2. Apply a light coat of multi-purpose grease PN 4318063 to the inside of the pilot bushing.
NOTE: FAILURE TO PERFORM THIS PROCEDURE MAY RESULT IN ONE OR MORE OF THE
FOLLOWING SYMPTOMS/CONDITIONS - HIGH SHIFTING EFFORT INTO FIRST AND
SECOND GEAR, GEAR CLASH INTO REVERSE AND LOW GEARS, PILOT BUSHING NOISE
AND CLUTCH DRAG.
POLICY: INFORMATION ONLY
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Testing and
Inspection
Fig. 4 Rear Axle & Differential Diagnosis
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Service and
Repair > Differential Bearing Retainer
Differential Assembly: Service and Repair Differential Bearing Retainer
Fig. 14 Differential bearing retainer
1. Using suitable screwdriver, remove differential bearing retainer seal. Do not damage oil baffle.
2. Using suitable press, handle No. C-4171 and seal installer L-4520 (inverted), install differential
bearing retainer seal.
3. Using tool L-4518, remove differential bearing retainer cup. Do not damage oil baffle.
4. Using suitable press, handle No. C-4171 and seal installer L-4520 (inverted), install oil baffle.
5. Select suitable shim. Refer to ADJUSTMENT PROCEDURES.
6. Using suitable press, handle No. C-4171 and seal installer L-4520 (inverted), install shim and
differential bearing retainer cup.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Service and
Repair > Differential Bearing Retainer > Page 4057
Differential Assembly: Service and Repair Differential
Fig. 17 Checking side gear endplay
If transaxle case, differential bearing retainer, extension housing, differential case or differential
bearings are being replaced, the shim thickness must be determined. Refer to Transmission and
Drivetrain/Differential/Adjustments.
1. Using suitable puller, remove differential bearing cones.
2. Install differential bearing cones using suitable press.
3. If necessary, remove ring gear attaching bolts and ring gear. If ring gear bolts are removed, they
must be replaced. Torque ring gear attaching bolts to 65 ft. lbs.
4. Remove pinion shaft roll pin using suitable punch and hammer, then the pinion shaft.
5. Remove pinion gears, side gears and thrust washers from differential case.
6. Clean and inspect all parts. Replace as necessary.
7. Install thrust washers, side gears and pinion gears.
8. Install spacer tool C-4996. Move side gear up and down to determine side gear endplay.
Endplay should be within 0.001-0.013 inch. If not within specifications, replace thrust washers.
Thrust washers are available in 0.032, 0.037, 0.042 and 0.047 inch thicknesses.
9. Repeat step 8 for other side gear.
10. Reverse steps 1 through 4 to complete assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair
Axle Shaft: Service and Repair
REMOVAL
1. Remove cotter pin, locknut and spring washer from wheel hub. 2. Loosen hub nut with brakes
applied. 3. Raise and support vehicle, then remove wheel and tire assembly.
Fig. 18 Speedometer pinion removal
4. If removing right driveshaft, speedometer pinion must be removed prior to driveshaft removal.
5. Remove ball joint stud to steering knuckle clamp bolt, then separate ball joint stud from steering
knuckle using a suitable pry bar.
CAUTION: Use caution not to damage ball joint or CV joint boots.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 4063
6. Separate outer CV joint splined shaft from hub by holding CV housing while moving knuckle/hub
assembly away.
CAUTION: Do not use pry bar to separate hub from shaft or damage to outer wear sleeve on CV
joint may occur.
7. Support driveshaft assembly at CV joint housing and remove by pulling outward on inner CV
joint housing. Do not pull on shaft. 8. Remove driveshaft assembly from vehicle.
INSTALLATION
Caution: During any service procedures where knuckle and driveshaft are separated, clean seal
and wear sleeve with suitable solvent, and apply a suitable lubricant to both components. Solvent
must not touch the boot.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 4064
1. Hold inner joint assembly at housing while aligning and guiding inner joint spline into transaxle.
2. Push knuckle/hub assembly out and install outer CV joint shaft into hub.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 4065
3. Install knuckle assembly on ball joint stud, then clamp bolt. Tighten bolt to 70 ft lbs. Steering
knuckle clamp bolt is prevailing torque type.
Original, or equivalent bolt must be installed during assembly.
4. Install speedometer pinion, right driveshaft only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 4066
5. Fill transaxle with suitable transaxle fluid. 6. Install washer and hub nut, then tighten hub nut to
200 ft lbs. Install nut lock and cotter pin. 7. If inboard boot appears collapsed or deformed following
installation, vent inner boot by inserting a round tipped, small diameter rod between boot
and shaft. As venting occurs, boot will return to normal shape.
8. Install wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service
Constant Velocity Joint: Service and Repair Inner CV Joint Service
DISASSEMBLY
Driveshaft assembly should be identified before starting service procedure. Refer to SYSTEM I.D..
Fig. 7 Driveshaft components
1. Remove boot clamps, then pull back boot to gain access to the tripod
Fig. 8 Removing inner CV joint tripod. G.K.N units
2. On G.K.N. units, place driveshaft assembly in vise and hold housing as shown. Lightly compress
CV joint retention spring while bending tabs back with suitable pliers, then remove tripod from
housing.
Fig. 9 Removing inner CV joint tripod. Citroen units
3. On CITROEN units, separate tripod from housing by slightly deforming retaining ring at three
locations. If necessary, cut retaining ring from housing and install replacement retaining ring by
rolling the edge into machined groove in housing with suitable punch. When removing tripod
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4071
from housing, secure rollers. After tripod has been removed, secure assembly with tape.
4. On all models, remove snap ring from end of shaft, then remove tripod using brass punch.
Inspection Remove grease from assembly and inspect bearing race, tripod components, spring,
spring cup and spherical end of connecting shaft for excessive wear or damage and replace if
necessary.
ASSEMBLY
1. Slide small end of boot over shaft, then place clamp over groove on boot.
2. Install tripod on shaft, then lock tripod assembly on shaft by installing retaining ring in shaft
groove. On G.K.N. units, slide tripod on shaft with non-chamfered end facing tripod retainer ring
groove.
3. Distribute packets of special grease provided in boot clamp kit as follows: a.
On G.K.N. units, distribute one packet of grease in the housing and remaining packets into the
boot.
b. On CITROEN units, distribute 2/3 of a packet of grease into the boot and remaining amount in
the housing.
4. Position spring, with spring cup attached to exposed end, into spring pocket. Place a small
amount of grease on spring cup.
5. Install tripod into housing as follows: a.
On G.K.N. units, slip tripod into housing and bend retaining tabs down to their original position.
Ensure retaining tabs hold tripod in housing.
b.
On CITROEN units, remove tape holding rollers and needle bearings in place, then install tripod
assembly into housing. Reform old ring or install new retainer ring. Ensure retaining collar holds
tripod in housing. If new retainer ring is installed, hold ring in position with two C-clamps and roll the
edge into machined groove in housing using a suitable punch.
6. On all models, ensure proper spring positioning. The spring must remain centered in the housing
spring pocket when tripod is installed and seated in the spring cup.
7. Position boot over boot groove in housing, then install clamp.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4072
Constant Velocity Joint: Service and Repair Outer CV Joint Service
Disassembly
Driveshaft assembly should be identified before starting service procedure. Refer to SYSTEM I.D..
Fig. 7 Driveshaft components
1. Remove boot clamps, then pull back boot to gain access to joint.
2. Clean grease from joint.
Fig. 16 Removing outer CV joint from shaft
3. On all models except S.S.G. units, place driveshaft assembly in suitable vise and support outer
joint. Remove outer joint from shaft by tapping top of joint body with a soft hammer.
4. Remove circlip from shaft groove and discard.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4073
Fig. 17 Circlip retainer in cross. S.S.G. units
5. On S.S.G. units, loosen damper weight bolts, slide it and boot towards inner joint. Remove
circlip, then joint from shaft.
6. On all units, if constant velocity joint is operating satisfactorily and grease does not appear
contaminated, refer to ASSEMBLY.
7. If constant velocity joint is noisy or badly worn, replace entire unit. The repair kit will include boot,
clamps, circlip and lubricant. Clean and inspect joint outlined in the following steps.
Fig. 18 Ball removal. Outer CV joint
8. Clean surplus grease and mark relative position of inner cross, cage and housing with a dab of
paint.
9. Hold joint vertically in a soft jawed vise.
10. Press downward on one side of the inner race to tilt cage and remove ball from opposite side. If
joint is tight, use a hammer and brass drift to tap inner race. Do not strike the cage. Repeat this
step until all balls have been removed. A screwdriver may be used to pry balls loose.
Fig. 19 Cage & cross assembly removal. Outer CV joint
11. Tilt cage assembly vertically and position the two opposing, elongated cage windows in area
between ball grooves. Remove cage and inner race assembly by pulling upward from the housing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4074
Fig. 20 Removing cross from cage. Outer CV joint
12. Rotate inner cross 90° to cage and align one of the race spherical lands with an elongated cage
window. Raise land into cage window and remove inner race by swinging outward.
Inspection
1. Check housing ball races for excessive wear.
2. Check splined shaft and nut threads for damage.
3. Inspect the balls for pitting, cracks, scouring and wearing. Dulling of the surface is normal.
4. Inspect cage for excessive wear on inner and outer spherical surfaces, heavy brinnelling of the
cage, window cracks and chipping.
5. Inspect inner race (cross) for excessive wear or scoring of ball races.
6. If any of the defects listed in steps 1 through 5 are found, replace the CV joint assembly as a
unit. Polished areas in races (cross and housing) and cage spheres are normal and do not indicate
a need for joint replacement unless they are suspected of causing noise and vibration.
Assembly
1. If removed, position wear sleeve on joint housing, then tap sleeve onto housing using oil seal
installer tool No. C-4698 or equivalent.
2. Lightly oil components, then align marks made during disassembly.
Fig. 21 Cage & cross assembled. G.K.N. units
Fig. 22 Cage & cross assembled. Citroen units
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4075
3. Align one of the inner race (cross) lands into cage window, then insert race into cage and pivot
90°.
Fig. 23 Installing cage & cross assembly into housing. Outer CV joint
Fig. 24 Cage & cross installed in housing. G.K.N. units
Fig. 25 Cage & cross installed in housing. Citroen units
Fig. 26 Cage & cross assembled. S.S.G. units
4. Align opposite elongated cage windows with housing land and insert cage assembly into
housing. Pivot cage 90° to complete installation. When properly assembled, the cross counterbore
should be facing outward from the joint on G.K.N. units. On CITROEN units, the cross and cage
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4076
chamfers will be facing outward from the joint, on S.S.G. joint the internal clip in cross will be facing
outward from the housing.
5. Apply lubricant to ball races between all sides of ball grooves.
6. Insert balls into raceway by tilting cage and inner race assembly.
Fig. 7 Driveshaft components
7. Slide small end of boot over shaft, then place clamp over groove on boot.
Fig. 27 Installing circlip. Outer CV joint
8. Insert new circlip in shaft groove. Do not over expand or twist circlip during assembly. On S.S.G.
unit has a reusable circlip retainer that is part of driver assembly.
9. Position joint housing on shaft, then engage by tapping sharply with a soft faced mallet.
10. Ensure snap ring is properly seated by attempting to pull joint from shaft.
11. Position boot over boot groove in housing, then install clamp.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service
Constant Velocity Joint Boot: Service and Repair Inner CV Joint Service
DISASSEMBLY
Driveshaft assembly should be identified before starting service procedure. Refer to SYSTEM I.D..
Fig. 7 Driveshaft components
1. Remove boot clamps, then pull back boot to gain access to the tripod
Fig. 8 Removing inner CV joint tripod. G.K.N units
2. On G.K.N. units, place driveshaft assembly in vise and hold housing as shown. Lightly compress
CV joint retention spring while bending tabs back with suitable pliers, then remove tripod from
housing.
Fig. 9 Removing inner CV joint tripod. Citroen units
3. On CITROEN units, separate tripod from housing by slightly deforming retaining ring at three
locations. If necessary, cut retaining ring from housing and install replacement retaining ring by
rolling the edge into machined groove in housing with suitable punch. When removing tripod
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4081
from housing, secure rollers. After tripod has been removed, secure assembly with tape.
4. On all models, remove snap ring from end of shaft, then remove tripod using brass punch.
Inspection Remove grease from assembly and inspect bearing race, tripod components, spring,
spring cup and spherical end of connecting shaft for excessive wear or damage and replace if
necessary.
ASSEMBLY
1. Slide small end of boot over shaft, then place clamp over groove on boot.
2. Install tripod on shaft, then lock tripod assembly on shaft by installing retaining ring in shaft
groove. On G.K.N. units, slide tripod on shaft with non-chamfered end facing tripod retainer ring
groove.
3. Distribute packets of special grease provided in boot clamp kit as follows: a.
On G.K.N. units, distribute one packet of grease in the housing and remaining packets into the
boot.
b. On CITROEN units, distribute 2/3 of a packet of grease into the boot and remaining amount in
the housing.
4. Position spring, with spring cup attached to exposed end, into spring pocket. Place a small
amount of grease on spring cup.
5. Install tripod into housing as follows: a.
On G.K.N. units, slip tripod into housing and bend retaining tabs down to their original position.
Ensure retaining tabs hold tripod in housing.
b.
On CITROEN units, remove tape holding rollers and needle bearings in place, then install tripod
assembly into housing. Reform old ring or install new retainer ring. Ensure retaining collar holds
tripod in housing. If new retainer ring is installed, hold ring in position with two C-clamps and roll the
edge into machined groove in housing using a suitable punch.
6. On all models, ensure proper spring positioning. The spring must remain centered in the housing
spring pocket when tripod is installed and seated in the spring cup.
7. Position boot over boot groove in housing, then install clamp.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4082
Constant Velocity Joint Boot: Service and Repair Outer CV Joint Service
Assembly
1. If removed, position wear sleeve on joint housing, then tap sleeve onto housing using oil seal
installer tool No. C-4698 or equivalent.
2. Lightly oil components, then align marks made during disassembly.
Fig. 21 Cage & cross assembled. G.K.N. units
Fig. 22 Cage & cross assembled. Citroen units
3. Align one of the inner race (cross) lands into cage window, then insert race into cage and pivot
90°.
Fig. 23 Installing cage & cross assembly into housing. Outer CV joint
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4083
Fig. 24 Cage & cross installed in housing. G.K.N. units
Fig. 25 Cage & cross installed in housing. Citroen units
Fig. 26 Cage & cross assembled. S.S.G. units
4. Align opposite elongated cage windows with housing land and insert cage assembly into
housing. Pivot cage 90° to complete installation. When properly assembled, the cross counterbore
should be facing outward from the joint on G.K.N. units. On CITROEN units, the cross and cage
chamfers will be facing outward from the joint, on S.S.G. joint the internal clip in cross will be facing
outward from the housing.
5. Apply lubricant to ball races between all sides of ball grooves.
6. Insert balls into raceway by tilting cage and inner race assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4084
Fig. 7 Driveshaft components
7. Slide small end of boot over shaft, then place clamp over groove on boot.
Fig. 27 Installing circlip. Outer CV joint
8. Insert new circlip in shaft groove. Do not over expand or twist circlip during assembly. On S.S.G.
unit has a reusable circlip retainer that is part of driver assembly.
9. Position joint housing on shaft, then engage by tapping sharply with a soft faced mallet.
10. Ensure snap ring is properly seated by attempting to pull joint from shaft.
11. Position boot over boot groove in housing, then install clamp.
Disassembly
Driveshaft assembly should be identified before starting service procedure. Refer to SYSTEM I.D..
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4085
Fig. 7 Driveshaft components
1. Remove boot clamps, then pull back boot to gain access to joint.
2. Clean grease from joint.
Fig. 16 Removing outer CV joint from shaft
3. On all models except S.S.G. units, place driveshaft assembly in suitable vise and support outer
joint. Remove outer joint from shaft by tapping top of joint body with a soft hammer.
4. Remove circlip from shaft groove and discard.
Fig. 17 Circlip retainer in cross. S.S.G. units
5.
On S.S.G. units, loosen damper weight bolts, slide it and boot towards inner joint. Remove circlip,
then joint from shaft.
6. On all units, if constant velocity joint is operating satisfactorily and grease does not appear
contaminated, refer to ASSEMBLY.
7. If constant velocity joint is noisy or badly worn, replace entire unit. The repair kit will include boot,
clamps, circlip and lubricant. Clean and inspect joint outlined in the following steps.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4086
Fig. 18 Ball removal. Outer CV joint
8. Clean surplus grease and mark relative position of inner cross, cage and housing with a dab of
paint.
9. Hold joint vertically in a soft jawed vise.
10. Press downward on one side of the inner race to tilt cage and remove ball from opposite side. If
joint is tight, use a hammer and brass drift to tap inner race. Do not strike the cage. Repeat this
step until all balls have been removed. A screwdriver may be used to pry balls loose.
Fig. 19 Cage & cross assembly removal. Outer CV joint
11. Tilt cage assembly vertically and position the two opposing, elongated cage windows in area
between ball grooves. Remove cage and inner race assembly by pulling upward from the housing.
Fig. 20 Removing cross from cage. Outer CV joint
12. Rotate inner cross 90° to cage and align one of the race spherical lands with an elongated cage
window. Raise land into cage window and remove inner race by swinging outward.
Inspection
1. Check housing ball races for excessive wear.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4087
2. Check splined shaft and nut threads for damage.
3. Inspect the balls for pitting, cracks, scouring and wearing. Dulling of the surface is normal.
4. Inspect cage for excessive wear on inner and outer spherical surfaces, heavy brinnelling of the
cage, window cracks and chipping.
5. Inspect inner race (cross) for excessive wear or scoring of ball races.
6. If any of the defects listed in steps 1 through 5 are found, replace the CV joint assembly as a
unit. Polished areas in races (cross and housing) and cage spheres are normal and do not indicate
a need for joint replacement unless they are suspected of causing noise and vibration.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Specifications
Wheel Bearing: Specifications Nut Torque
Nut Torque
Front Axle Nut Torque 180 ft.lb
Rear Bearing Nut Torque 270 in.lb
+/- 30 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Specifications > Page 4091
Wheel Bearing: Adjustments
Fig. 3 Wheel bearing assembly
1. Raise and support rear of vehicle.
2. Tighten adjusting nut to 27 to 34nm (240 to 300 in. lbs.) while rotating wheel.
3. Stop wheel and loosen adjusting nut.
4. Tighten adjusting nut finger tight. End play should be 0.0001-0.0020 inch.
5. Install castle lock with slots aligned with cotter pin hole.
6. Install cotter pin and grease cap.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front
Wheel Bearing: Service and Repair Front
Permanent Bearings
REMOVAL
Fig. 15 Removing hub & bearing assembly
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and drive shaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and
washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6.
Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the
caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor,
then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV
joint during this procedure.
Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported.
9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as
shown.
10. Remove hub and bearing assembly.
INSTALLATION
Fig. 16 Seal installation
1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using
oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of
seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse
driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve
using a suitable lubricant.
4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint
stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install
tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install
rotor, then position caliper over rotor and guide hold-down spring below machined guides on
knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut,
then with brakes applied, tighten nut to specifications.
10. Install spring washer, locknut and cotter pin.
Replaceable Bearings
REMOVAL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 4094
Fig. 14 Hub removal
Fig. 12 Removing bearing from knuckle
1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or
equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer.
4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle
using tool No. C-4811-2 or equivalent.
INSTALLATION
Fig. 13 Installing bearing into knuckle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 4095
Fig. 14 Installing hub into knuckle
1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer.
Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No.
C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No.
C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front > Page 4096
Wheel Bearing: Service and Repair Rear
REMOVAL
1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Remove cotter pin, nut
lock, spring washer and hub nut. 3. Remove half shaft flange retaining bolts. 4. Half shaft is spring
loaded, compress inner half shaft joint slightly pulling down to clear rear carrier output shaft. 5.
Remove half shaft by pulling half shaft assembly inboard. 6. Remove wheel bearing mounting
bolts, then wheel bearing and hub assembly. 7. Replace grease seal if needed.
INSTALLATION
1. If grease seal was removed, install a new seal using installer tool No. 6536-A or equivalent.
Lubricate circumference of seal before installation. 2. Install washer and hub nut. With brakes
applied, torque to 180 ft. lbs. 3. Install spring washer, nut lock and cotter pin. 4. Install hub and
bearing assembly. Torque bolts in a crossing pattern to 96 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Permanent Bearings
Wheel Hub: Service and Repair Permanent Bearings
REMOVAL
Fig. 15 Removing hub & bearing assembly
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and drive shaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and
washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6.
Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the
caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor,
then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV
joint during this procedure.
Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported.
9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as
shown.
10. Remove hub and bearing assembly.
INSTALLATION
Fig. 16 Seal installation
1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using
oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of
seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse
driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve
using a suitable lubricant.
4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint
stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install
tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install
rotor, then position caliper over rotor and guide hold-down spring below machined guides on
knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut,
then with brakes applied, tighten nut to specifications.
10. Install spring washer, locknut and cotter pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Permanent Bearings > Page 4101
Wheel Hub: Service and Repair Replaceable Bearings
REMOVAL
Fig. 14 Hub removal
Fig. 12 Removing bearing from knuckle
1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or
equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer.
4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle
using tool No. C-4811-2 or equivalent.
INSTALLATION
Fig. 13 Installing bearing into knuckle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Service and Repair > Permanent Bearings > Page 4102
Fig. 14 Installing hub into knuckle
1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer.
Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No.
C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No.
C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
A-413 / A-670
Flex plate to crankshaft bolts ...............................................................................................................
.................................................... 95 Nm ( 70 ft-lbs )
A-604
Drive plate to crankshft bolts ...............................................................................................................
................................................... 95 Nm ( 70 ft-lbs )
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Service and Repair
Case: Service and Repair
Fig. 8 Intermediate bearing retaining strap removal
1. Remove input shaft front bearing cup using suitable press, then press in new bearing cup.
2. Remove intermediate shaft front bearing retaining strap, then using puller tool C-4660 and screw
C-4660-2A, remove front bearing and oil feeder. When installing bearing, letters on bearing should
face away from case.
3. Install intermediate shaft front bearing and oil feeder with suitable press.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Service and Repair
Extension Housing: Service and Repair
Fig. 15 Extension housing
1. Pry extension housing seal from extension housing using suitable screwdriver.
2. Using suitable hammer, handle No. C-4171 and seal installer L-4520 (inverted), install extension
housing oil seal.
3. Remove extension housing bearing cup using tool L-4518. Do not damage oil baffle.
4. Using suitable press, handle No. C-4171 and seal installer L-4520, install oil baffle and extension
housing bearing cup.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications
Fluid - M/T: Specifications
All..........................................................................................................................................................
.........................5W-30 SF/CC, SF/CD, SG/CD, SG
CAPACITY, Refill: 5-speed A525.........................................................................................................
................................................................................2.1 Liters 4.6 Pints
5-speed A520, A555, A569 .................................................................................................................
.................................................2.3 Liters 4.8 Pints
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T >
Component Information > Technical Service Bulletins > Clutch Splines & Pilot Bushing - Lubrication
Input Shaft: Technical Service Bulletins Clutch Splines & Pilot Bushing - Lubrication
Models
AA, AB, AD, AG, AH, AJ, AK, AL, AN, AP, AQ, AS Bodies Through 1989
Subject
Clutch Splines/Pilot Bushing Lubrication
Index
CLUTCH
Date
January 16, 1989
No.
06-01-89
P-0046 (C06-01-9) BODY CODE LEGEND
AA - Spirit/Acclaim AB - Dodge Ram Van/Wagon
AD - Dodge Ram Pickup/Ram Charger AG - Daytona
AH - LeBaron/LeBaron GTS AJ - LeBaron
AK - Aries/Reliant AL - Omni/Horizon
AN - Dodge Dakota/Dakota Sport AP - Shadow/Sundance
AQ - Chrysler TC AS - Caravan/Voyager
This Technical Service Bulletin supersedes ALL previous Service Technical Publications through
1989 covering the lubrication of the clutch splines and pilot bushing. The procedures outlined in this
bulletin apply to all domestic cars and trucks equipped with manual transmissions and transaxles.
SERVICE PROCEDURE
NOTE: THIS PROCEDURE SHOULD BE PERFORMED ANYTIME THE
TRANSMISSION/TRANSAXLE IS REMOVED FROM THE ENGINE AND/OR CLUTCH SERVICE
IS PERFORMED.
CLUTCH SPLINES
1. Thoroughly clean the input shaft clutch splines and clutch disc splines, they must be free of any
dirt or rust.
2. Apply a light coat of wheel bearing grease PN 4318064 evenly to the entire length of the
exposed input shaft splines. Be sure all excessive lubricant is removed.
NOTE: THE USE OF ALTERNATIVE OIL BASED LUBRICANTS IS NOT RECOMMENDED AS
THESE LUBRICANTS WILL EVENTUALLY DRY UP OR BURN OFF LEAVING ONLY A DRY
RESIDUE.
REAR WHEEL DRIVE VEHICLES - PILOT BUSHING
1. Thoroughly clean the pilot bearing journal at the end of the input shaft and the inside of the pilot
bushing.
2. Apply a light coat of multi-purpose grease PN 4318063 to the inside of the pilot bushing.
NOTE: FAILURE TO PERFORM THIS PROCEDURE MAY RESULT IN ONE OR MORE OF THE
FOLLOWING SYMPTOMS/CONDITIONS - HIGH SHIFTING EFFORT INTO FIRST AND
SECOND GEAR, GEAR CLASH INTO REVERSE AND LOW GEARS, PILOT BUSHING NOISE
AND CLUTCH DRAG.
POLICY: INFORMATION ONLY
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T >
Component Information > Technical Service Bulletins > Page 4120
Input Shaft: Service and Repair
Fig. 16 Input shaft rear bearing cone installation
If transaxle case, input shaft seal retainer, bearing retainer plate, rear end cover, input shaft or
input shaft bearings are being replaced, the shim thickness must be determined. Refer to
Transmission and Drivetrain/Manual Transmission/Transaxle/Input Shaft/Adjustments.
1. Using puller C-293 and adapters C-293-45, remove input shaft rear bearing cone.
2. Install input shaft rear bearing cone, using suitable press and tool L-4171.
3. Using puller C-293 and adapter C-293-50, remove input shaft front bearing cone.
4. Install input shaft front bearing cone, using suitable press and tool L-4462.
5. Remove input shaft rear bearing cup, using suitable press, handle C-4171 and installer L-4520.
6. Bolt on bearing support plate, then install input shaft rear bearing cup, using suitable press,
handle C-4171 and installer L-4520. Press in bearing cup until it bottoms.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T >
Component Information > Adjustments
Shift Linkage: Adjustments
Fig. 4 Lock pin replacement
1. Remove lock pin from transaxle selector shaft housing.
2. Reverse lock pin so long end is facing downward, then insert lock pin into same threaded hole
while pushing selector shaft into selector housing.
Fig. 5 Gear shift linkage
3. Remove gearshift knob, retaining nut and pull-up ring.
4. Remove boot assembly from console, then the console.
Fig. 6 Cable adjusting pins
5. Fabricate two cable adjusting pins as shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T >
Component Information > Adjustments > Page 4124
Fig. 7 Selector cable adjustment
6. Adjust selector cable and torque adjusting screw to 55 inch lb. Selector cable adjusting screw
must be properly tightened.
Fig. 8 Crossover cable adjustment
7. Adjust crossover cable and torque adjusting screw to 55 inch lbs. Crossover cable adjusting
screw must be properly tighten.
8. Install console and boot assembly, then the pull-up ring, retaining nut and gearshift knob. Apply
suitable locking compound to retaining nut and tighten finger tight plus one turn.
9. Remove lock pin from selector shaft housing, then reinstall lock pin so long end is up in selector
shaft housing. Torque lock pin to 105 inch lbs.
10. Check for proper operation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T >
Component Information > Adjustments > Page 4125
Shift Linkage: Service and Repair
Fig. 13 Selector shaft housing
1. Remove selector shaft snap ring and boot, then selector shaft seal.
2. Remove selector shaft E-clip, then slide selector shaft from housing.
3. Disassemble selector shaft housing as necessary.
4. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4136
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4137
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4138
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
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Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
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182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4139
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4140
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4141
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 4146
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 4151
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting
Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
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211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 4156
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
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Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4162
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4163
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4164
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4165
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4166
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4167
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 4172
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 4177
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting
Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 4182
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4187
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4188
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4189
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4195
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4196
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4197
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page
4200
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4201
Control Module: Diagrams
Part 1 Of 11
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and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4202
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4203
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4204
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4205
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4206
Part 6 Of 11
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and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4207
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4208
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4209
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4210
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4211
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604
Control Module: Description and Operation A604
DESCRIPTION
This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped
similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code
memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 4214
Control Module: Description and Operation 41TE
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 4215
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 -
Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
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4218
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4222
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4223
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
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and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4224
Transmission Control System Relay: Description and Operation
DESCRIPTION
This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to
the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay,
voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in
this mode, only second gear, reverse and neutral are available.
This relay may also be referred to as the Safety Shutdown Relay.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations
Transmission Position Relay: Component Locations
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations >
Page 4229
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the
transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps.
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Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4243
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4244
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4245
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range
Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range
Sensor - Production Change > Page 4251
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range
Sensor - Production Change > Page 4252
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4257
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4258
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4259
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4265
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4266
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission
Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission
Solenoid and Pressure Switch Assembly > Page 4269
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission
Solenoid and Pressure Switch Assembly > Page 4270
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission
Solenoid and Pressure Switch Assembly > Page 4271
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch >
Page 4274
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation >
Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation >
Transmission Range Sensor > Page 4277
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor,
Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor,
Transmission Range > Page 4280
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor,
Transmission Range > Page 4281
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor,
Transmission Range > Page 4282
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 4291
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
4296
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
4297
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
4298
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of
Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of
Cruise Control > Page 4304
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4309
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4310
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4311
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4312
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output
Speed Sensor
Transmission Speed Sensor: Description and Operation Output Speed Sensor
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output
Speed Sensor > Page 4315
Transmission Speed Sensor: Description and Operation Turbine Speed Sensor
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque
convertor turbine).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 4316
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation
Transmission Temperature Sensor/Switch: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To
Stop
Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To
Stop > Page 4331
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When
Coming To Stop
Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop
NO: 21-10-96
GROUP: Transmission
DATE: Jul. 5, 1996
SUBJECT:
Ratcheting Sound During Garage Shifts and When Coming to A Stop
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1996 (FJ) Sebring/Avenger/Talon
1996 (GS) Chrysler Voyager (European Market)
1995 - 1996 (JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a
stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On
some vehicles this sound may be more noticeable than others because of variations in sealing of
the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED
FOR THIS CONDITION.
DIAGNOSIS:
With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid
operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear.
If the racheting sound is confirmed, perform the Repair Procedure.
PARTS REQUIRED:
AR 82300234 Sealant, Mopar RTV
REPAIR PROCEDURE:
This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle
case.
NOTE:
THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL
REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL
CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR
DURABILITY OF THE TRANSAXLE.
1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or
other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air
cleaner may be helpful in gaining access to the area.
NOTE:
DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the
electrical connectors/components.
2. Blow the area dry with compressed air.
3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield
and the transaxle case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When
Coming To Stop > Page 4337
4. Lower the vehicle and install the air cleaner if applicable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-90-95-90 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > Page 4338
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical
Service Bulletins > Page 4339
Transmission Solenoid Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 >
Converter Lock Up Solenoid - Bucking/Surging
Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 >
Converter Lock Up Solenoid - Bucking/Surging > Page 4348
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 >
Converter Lock Up Solenoid - Bucking/Surging > Page 4349
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 >
Converter Lock Up Solenoid - Bucking/Surging > Page 4350
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290
> Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging
Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging
Models
1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies
Subject
Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines.
Index
DRIVEABILITY
Date
February 12, 1990
No.
18-02-90
P-205 (C18-27-9) BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG
- DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic
transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4
speed automatic transmission.
SYMPTOM/CONDITION
A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur
under light deceleration conditions, especially when cresting a hill.
DIAGNOSIS
The above conditions can be diagnosed by disconnecting the transmission lock-up torque
converter solenoid, and driving the vehicle under the above conditions. If the problem goes away,
follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test
Procedure for correction. PARTS REQUIRED
Driveability Kit PN 4419447
Consists of:
1 Wiring Jumper Assembly PN 4400768
1 Lock-Up Solenoid Cap PN 4419446
2 Tie Wrap PN 6015756
1 Authorized Modification Label PN 4275086
REPAIR PROCEDURE
The following procedure involves disconnecting the lock-up torque convertor solenoid. The
customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2
miles per gallon may be noticed, depending on driving conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290
> Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4356
FIGURE A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290
> Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4357
FIGURE B
1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located
directly behind the transmission dipstick (Figures A and B).
2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in
Step 1.
3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring)
under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original
lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A).
3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it
loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two
places using tie wrap, PN 6015756 (Figure B).
4. Install supplied cap, PN 4419446, onto lock-up solenoid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290
> Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4358
FIGURE C
5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and
attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-96-01-90 0.2 Hrs.
FAILURE CODE: AM - Authorized modification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Component Locations
Torque Converter Clutch Solenoid: Component Locations
Part Throttle Unlock Solenoid (3speed)
LH Side Of Engine Compartment 3 Speed Automatic
RH Side Of Transaxle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Component Locations > Page 4361
Applicable to: 3 Speed A-413 Automatic Transaxle
4 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Component Locations > Page 4362
Electrical Connections, 3 Speed Automatic
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Page 4363
Torque Converter Clutch Solenoid: Description and Operation
Part Throttle Unlock Solenoid (3 Speed Automatic)
This solenoid is controlled by the engine controller. The engine controller applies and removes the
ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque
converter is only locked up when the transmission is in direct drive and when the throttle position is
not fluctuating. If the engine controller receives a signal from the throttle position sensor that an
increase or decrease in throttle is needed (when the transmission gear selector is in direct drive),
the engine controller will disengage the part throttle solenoid causing the lock-up torque converter
to be disengaged.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4374
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4375
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4376
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4377
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4378
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4379
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 4384
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift
Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 4389
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting
Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 4394
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality
Technical Service Bulletin # 182495 Date: 950623
A/T - Poor Shift Quality
NO: 18-24-95
GROUP: Veh. Performance
DATE: Jun. 23, 1995
SUBJECT: Improved Transmission Shift Quality
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED
JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN
MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART
NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible
1990 - 1991 (AQ) Chrysler TC
**1989** - 1995 (AS) Caravan/Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
**1995 (FJ) Sebring/Avenger/Talon**
1995 (JA) Cirrus/Stratus
1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.
SYMPTOM/CONDITION:
1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES**
AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH
10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED
CONVERTOR CLUTCH (EMCC).
Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41
MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit
a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque
converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to
the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these
symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC
operation will be temporarily enabled.
**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE
OCT. 24. 1994 (MDH 10-24-XX).
The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for
all vehicles dating back to the 1989 model year. The shift quality improvements and default issues
that will be corrected by the new TCM calibration are:
1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then
the driver tips back into the throttle to accelerate, a noticeable bump may be felt.
2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1
downshifts.
3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early
1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission
responsiveness may be encountered under normal operating conditions. The transmission may not
release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35
MPH to 50 MPH.
4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or
2-1 kickdowns at speeds less than 25 MPH.
5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds,
while using the speed control.
6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than
2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are
caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or
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Page 4400
malfunctioning PRNDL or neutral start switch.
7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY
DISCONNECT: All transmission learned values are reset to the factory default values if battery
power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory
after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is
installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI)
on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION
FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE
CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD
CAUSE POOR INITIAL SHIFT QUALITY.
8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP
OUT: The new service calibration change corrects this condition (this condition was also covered in
Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).
9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump
prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are
de-sensitized to reduce erroneous limp-in conditions.
Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly
from the OD position to the N position. This typically happens if the operator has a tendency to rest
his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD.
The new software detects this maneuver and shifts the transaxle into Neutral rather than setting
code a 21 fault and the subsequent limp-in conditions.
Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may
set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch
and cause a delay on garage shifts. The new software prevents this fault code from being set in
error and the transaxle going into the limp-in mode.
Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure
to achieve pump prime) has been added and does not trigger a limp-in condition.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: LABOR OPERATION NO:
21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test)..................................
..........................................................................................................................0.7 Hrs.
FAILURE CODE: FM - Flash Module
LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te
st)..........................................................................................................................................................
..0.8 Hrs.
FAILURE CODE: P8 - New Part
RELATED OPERATIONS: 21-19-01-50 Fluid Replace
Procedure..................................................................................................................................1.0
Hrs. 21-19-01-51 Pinion Factor............................................................................................................
.......................................0.2 Hrs. 21-19-01-52 Quick Learn.................................................................
....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49
Modification....................................................................................................................................0.1
Hrs.
Diagnosis
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate
Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as
designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for
future reference and repair as necessary. Inspect the transmission fluid for the correct level and red
color.
If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color
and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed
above, perform REPAIR PROCEDURE NO. 1.
If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR
PROCEDURE NO. 2 beginning on page 9.
EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 4401
1 CH5500 Flash Programming Kit
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7025 DIN Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
AR 4504048 Package, Oil Filter 41TE
AR 4796730 Package, Oil Filter 42LE
AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176
PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:
PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION
AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC,
AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR
4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with
3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708
1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR
4467721 Fluid, Mopar Automatic Transmission - Type 7176
NOTE:
WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's:
4796121, 4796122, 4796123, and 4796124
When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at
CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is
driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake
pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd
gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD
enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will
change between enabled/disabled OD each time the brake pedal is pushed.
In addition to the normal TCM installation procedure, perform the following steps:
A. Remove the cover from the wiring harness connector at the TCM.
B. Locate CAVITY 49 of the TCM harness connector.
C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room
at each of the cut ends of the wire to install a
piece of shrink tubing, P/N 4778570.
D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the
midpoint of the shrink tubing. Use an electric heat
gun to shrink the tubing and seal the wire ends.
E. Install the TCM wiring harness connector cover.
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Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 4402
Repair Procedure No. 1
REPAIR PROCEDURE NO. 1
This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it
cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the
Quick Learn procedure.
1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the
TCM.
If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers
listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be
flashed.
NOTE:
THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING
REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER
INSTALLED.
2. Connecting the MDS and DRB III to the vehicle (Refer to illustration).
A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle.
B) Connect the controller programming harness (CH2500) from the Flash Programming Kit
(CH5500) to the TOM on the vehicle.
C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness
(CH2500)
D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable
(CH7025).
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS
DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then
press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT
MENU.
6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.
7. Enter the VIN and press NEXT MENU.
8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen.
Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94.
Press F2 to begin the programming and follow the instructions on the MDS screen.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 4403
If the controller on the vehicle has already been flashed, the MDS screen will state THIS
CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE
AVAILABLE. Follow instructions on the MDS screen to exit.
9. After programming is complete, disconnect the MDS and DRB III, then go to step 14.
VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED
10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM
that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed
into 1992 and prior vehicles). This is accomplished by:
A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:
1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select STAND-ALONE DRB III.
3) Select 94-95 DIAGNOSTICS.
4) Select TRANSMISSION.
5) Select MISCELLANEOUS.
6) Select TSB and follow the instructions on the DRB III screen.
B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the
individual vehicle) on 1993 - 1994 vehicles:
1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the
steering column.
2) Select SYSTEM
3) Select TRANSMISSION.
4) Select ADJUSTMENTS.
5) Select TSB and follow the instructions on the DRB II screen.
NOTE:
THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE
CHRYSLER RETURN CENTER.
11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB.
Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM.
Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure
to install the revised TCM.
12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later
vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE
transaxles, 1992 and prior models or if the TCM was flashed).
A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the
steering column and the MDS.
B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.
C) Select EATX DIAGNOSTICS.
D) Select EATX STATE DISPLAY and press F2.
E) Select ADJUSTMENTS and press F2.
F) Select PINION FACTOR and press F2.
G) Follow the instructions on the MDS screen.
NOTE:
BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE
SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID
SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO
PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL
SHIFT QUALITY.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality >
Page 4404
13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle
or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and
prior vehicles).
A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place
shift lever in Neutral. Apply the parking brake
and let the engine idle.
B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.
C) Follow the instructions on the MDS screen.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW.
14. Type the necessary information on the Authorized Modification Label and attach the label near
the Vehicle Emission Control Information (VECI) Label.
15. Type the necessary information on the "Authorized Software Update Label" and attach it to the
TCM and cover label with a clear plastic sticker.
Repair Procedure No. 2
REPAIR PROCEDURE NO. 2:
This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can
not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the
transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing
the Quick Learn procedure.
1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1.
2. Disconnect the DRB III and MDS from the vehicle.
3. Change the transmission fluid using following the procedure:
A) Raise the vehicle with an appropriate hoist.
B) Clean the transaxle oil pan and mating area thoroughly.
C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area.
Clean the inside of the oil pan and magnet.
D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings
also may cause delayed garage shifts.
E) Separate the transaxle oil filter and O-ring from the valve body and discard.
F) Install the new oil filter specified in the Parts Required section of this TSB.
G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the
transaxle oil pan. Apply Mopar RTV sealant to the
underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
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Page 4405
NOTE:
USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID
TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH
SHUDDER.
H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.
I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the
service brakes applied, move the gear selector
lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.
J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the
level to 1/8 in. (3 mm) below the ADD mark
on dipstick.
K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should
be in the HOT range of the dipstick.
4. Drive the vehicle at least 10 miles.
5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.
6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This
also allows for additional fluid to drain from the transmission.
7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then
reinstall the transaxle oil filter and O-ring to the valve body.
8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.
NOTE:
THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.
9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st
Gear Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift
NO.: 21-16-93 Rev. A
GROUP: Transmission
DATE: Oct 8, 1993
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED.
CHANGES ARE HIGHLIGHTED BY **ASTERISKS**.
MODELS:
1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG)
Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town and Country
1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue
1992 (AP) Shadow/Sundance
SYMPTOM/CONDITION:
Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service
Manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st
Gear Downshift > Page 4410
TIME ALLOWANCE: Labor Operation No.
**08-19-05-99** 0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear
Downshift
Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift
NO.: 21-16-92
GROUP: Transmission
DATE: Nov. 2, 1992
SUBJECT: Harsh 2-1 Downshift 41TE Transaxle
MODELS:
1989-1992 (AA)
Acclaim/Spirit/LeBaron Sedan
(AC) Dynasty/New Yorker/New Yorker Salon
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country
1990-1992 (AY)
Imperial/New Yorker Fifth Avenue
SYMPTOM/CONDITION:
Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting
to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have
been made to the Transmission Control Module (TCM) for the 1993 model year that significantly
reduce 2-1 downshift harshness.
These new service controllers should only be used to repair vehicles with specific customer
dissatisfaction with harsh 2-1 downshifts.
DIAGNOSIS:
1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service
manual.
2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume
Indexes (CVI's) to determine if transaxle repair is appropriate.
3. Road test the vehicle to confirm 2-1 downshift harshness.
PARTS REQUIRED
REPAIR PROCEDURE:
This bulletin involves replacing the Transmission Control Module (TCM).
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear
Downshift > Page 4415
1. Use the procedure in the appropriate vehicle service manual to replace the TCM.
2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new
TCM to be realized, approximately one week of driving will need to be completed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs.
FAILURE CODE: 58 - Internal Defect
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive
Upshifting/Downshifting
Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting
Models
1989-90 AA, AC, AG, AJ, AS, & AY Bodies
Subject
A-604 Transmission Excessive Upshifting/ Downshifting
Index
TRANSMISSION
Date
April 9, 1990
No.
21-12-90
(C21-06-0) P-1042 BODY CODE LEGEND
AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ
- LEBARON COUPE/LEBARON CONVERTIBLE
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
AY - IMPERIAL/NEW YORKER FIFTH AVENUE
SYMPTOM/CONDITION
Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition
when the vehicle is fully loaded, driving up a grade or into a head wind.
This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior
(1989) model year A-604 controllers.
A new A-604 controller, PN 4557585, entered production late March 1990. The new controller
allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle
torque load changes.
DIAGNOSIS
Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does
not apply.
Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain
Diagnostic Procedure Manual.
If no fault codes are present, perform the following repair procedure.
If fault codes are present, they must be corrected and the corrections verified before performing the
following repair procedure. PARTS REQUIRED
1. 1 - Controller PN 4557585
REPAIR PROCEDURE
This repair involves the replacement of the transaxle controller.
1. Disconnect the negative battery cable.
2. Disconnect the 60-way connector from the controller.
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Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive
Upshifting/Downshifting > Page 4420
3. Remove the controller.
4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds.
5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds.
6. Reconnect the negative battery cable.
7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
08-19-05-96 0.6 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4425
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4426
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4427
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision
Technical Service Bulletin # 210889 Date: 890403
A/T Reaction Shaft Support - Revision
Models
1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle
Subject
Revised Reaction Shaft Support
Index
TRANSMISSION
Date
April 3, 1989
No.
21-08-89
P-1408 (C21-16-9)
Description
BODY CODE LEGEND
AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER
SYMPTOM/CONDITION
NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE
AUTOMATIC TRANSAXLE, PART NUMBER 4446659.
The procedure outlined in this bulletin should be followed if removal and disassembly of the
transaxle is required.
DIAGNOSIS
1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual
(#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A)
to determine if disassembly is required.
Use the following procedure when the transaxle is disassembled for repair.
PARTS REQUIRED
1 Repair package P/N 4549248
1 Gasket Package P/N 4504558
1 Controller (AS REQUIRED) P/N 5234678
NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT
CLUTCH HUB IS REQUIRED.
Input Clutch Retainer P/N 4431609
REPAIR PROCEDURE
1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the
following guidelines.
2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or
subsequent) controller.
Always check input shaft end play before disassembling the transaxle.
Step A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4433
FIGURE 1 - FRONT PUMP REACTION SHAFT
1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves,
replace it with the four ring reaction support supplied in the repair package (Figure 1). If the
reaction support that is removed from the transaxle has four ring grooves, the repair package is not
needed.
Step B
FIGURE 2 - INPUT CLUTCH RETAINER
1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer
as shown. If the bump is present, replace the retainer with a new one (P/N 4431609).
2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package.
When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on
the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent
input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the
compression of the Orings.
3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is
no difference in any of the O-rings. The color was added to facilitate assembly.
4. Inspect and replace any distressed (burned) clutch components as required.
Step C
1. Remove and discard the steel separator plate from the valve body.
2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the
package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow
to the overdrive clutch circuit.
Step D
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4434
1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play
to the service preferred setting of .005" to .015". The actual total end play specification is .005" to
.025" and is acceptable if the service preferred setting cannot be obtained.
Other Recommendations
1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or
petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not
use other kinds of petroleum based greases such as chassis grease that could plug critical orifices
or might be incompatible with transmission fluid.
2. Replace the torque convertor if a clutch failure has occurred.
3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or
a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY.
Replace it if necessary.
4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has
occurred.
5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is
the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be
used if ATF Plus is not available.
POLICY: Reimbursable within the limits of the warranty.
TIME ALLOWANCE: Labor Operation No.
21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs.
FAILURE CODE: 7H - Reaction shaft/supt. assy. failed
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4435
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module > Page 4438
Control Module: Locations Power Distribution Center
Power Distribution Center
Fuse Block
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4439
Control Module: Diagrams
Part 1 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4440
Part 2 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4441
Part 3 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4442
Part 4 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4443
Part 5 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4444
Part 6 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4445
Part 7 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4446
Part 8 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4447
Part 9 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4448
Part 10 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 4449
Part 11 Of 11
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > A604
Control Module: Description and Operation A604
DESCRIPTION
This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped
similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code
memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > A604 > Page 4452
Control Module: Description and Operation 41TE
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > A604 > Page 4453
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > General Information > Page 4456
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations
Transmission Control System Relay: Locations
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 4460
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 4461
Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 4462
Transmission Control System Relay: Description and Operation
DESCRIPTION
This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to
the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay,
voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in
this mode, only second gear, reverse and neutral are available.
This relay may also be referred to as the Safety Shutdown Relay.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information >
Locations > Component Locations
Transmission Position Relay: Component Locations
Back Up Lamp Relay / Transmission Control Relay
Back Up Lamp Relay / Transmission Control Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information >
Locations > Component Locations > Page 4467
Back Up Lamp Relay
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation
Transmission Mode Switch: Description and Operation
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the
transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4481
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4482
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4483
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4489
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4490
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4495
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4496
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4497
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change > Page 4503
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change > Page 4504
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4507
Park Neutral Position Switch / PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4508
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4509
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > PRNDL Switch
PRNDL Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > PRNDL Switch > Page 4512
Park / Neutral Position Switch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Description and Operation > Transmission Range Sensor
Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Description and Operation > Transmission Range Sensor > Page 4515
Transmission Position Switch/Sensor: Description and Operation PRNDL
The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed
electronic automatic transaxle.
It may have been replaced by a transmission range sensor (TRS).
Note: The Transmission Range Sensor is a different component from the Transmission Range
Switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > Sensor, Transmission Range
Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > Sensor, Transmission Range > Page 4518
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > Sensor, Transmission Range > Page 4519
Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > Sensor, Transmission Range > Page 4520
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 4529
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 4534
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 4535
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 4536
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control > Page 4542
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4547
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4548
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4549
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 4550
Input / Output Speed Sensor
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Description and Operation > Output Speed Sensor
Transmission Speed Sensor: Description and Operation Output Speed Sensor
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Description and Operation > Output Speed Sensor > Page 4553
Transmission Speed Sensor: Description and Operation Turbine Speed Sensor
A604 (41TE) 4 Speed Transaxle
DESCRIPTION
This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque
convertor turbine).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Description and Operation > Page 4554
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation
Transmission Temperature Sensor/Switch: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Description and Operation
ABS Light: Description and Operation
The Anti-Lock warning light will normally come on for approximately one to two seconds when the
ignition switch is first turned to the ON position.
Anytime the Controller Anti-Lock Brake (CAB) detects a condition which results in a shutdown of
the ABS function other than when the ignition switch is first turned on it will activate the ABS
warning lamp. When the light is on only the Anti-Lock function of the brake system is affected. The
standard brake system and ability to stop the vehicle will not be affected.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid
Accumulator > Component Information > Service and Repair > Depressurizing Hydraulic Accumulator
Brake Fluid Accumulator: Service and Repair Depressurizing Hydraulic Accumulator
NOTE:The ABS pump/motor assembly will keep the hydraulic accumulator charged to a pressure
between 1600-2000 psi anytime the ignition is in the ON position. The pump/motor cannot run if the
ignition is off or either battery cable is disconnected.
WARNING: The hydraulic accumulator should be depressurized before disassembling any portion
of the hydraulic system.
1. Turn ignition switch to the OFF position, or disconnect battery ground cable. 2. Pump brake
pedal a minimum of 40 times using approximately 50 pounds of pedal force. Pedal feel should
change noticeably when accumulator is
discharged.
3. After a definite increase in pedal effort is felt, pump pedal a few additional times. This will
remove all hydraulic pressure from the system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid
Accumulator > Component Information > Service and Repair > Depressurizing Hydraulic Accumulator > Page 4567
Brake Fluid Accumulator: Service and Repair Accumulator Replacement
1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair."
See: Depressurizing Hydraulic Accumulator
WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or
damage to painted surfaces.
2. Remove accumulator assembly. 3. Reverse procedure to install. Torque accumulator to 30 ft.
lbs., then turn ignition On and check for leaks.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump
> Component Information > Description and Operation
Brake Fluid Pump: Description and Operation
The Pump/Motor assembly is located under the hydraulic assembly at the rear lefthand side of the
engine compartment. This pump is electrically driven and takes low pressure brake fluid from the
hydraulic assembly reservoir and pressurizes it for storage in two accumulators for power assist
and anti-lock braking.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump
> Component Information > Description and Operation > Page 4571
Brake Fluid Pump: Service and Repair
1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair."
See: Brake Fluid Accumulator/Service and
Repair/Depressurizing Hydraulic Accumulator
WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or
damage to painted surfaces.
2. Remove air intake ducts from engine. 3. Loosen low pressure hose clamp at hydraulic unit. 4.
Disconnect high pressure fluid line clip from battery tray, then disconnect electrical connectors at
pump and near high and low pressure lines. 5. Disconnect high and low pressure lines from
hydraulic assembly. 6. Disconnect pump/motor to engine mount electrical connector, then remove
pump heat shield bolt from front of pump bracket. 7. Remove front heat shield, then the
pump/motor assembly. 8. Reverse procedure to install, noting the following:
a. Torque low pressure hose clamp to 10 inch lbs. b. Torque high pressure hose fitting to pump
assembly to 145 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations
Diagnostic Connector - ABS: Locations
This ABS system has a self diagnostic connector located under the lefthand side of the instrument
panel, left of the steering column. The diagnostic connector is a blue 6-way connector which can be
connected to a DRB II readout box.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations
Electronic Brake Control Module: Locations
The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine
compartment. The CAB uses the wheel speed information from the wheel speed sensors to control
the ABS system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 4578
Electronic Brake Control Module: Description and Operation
The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine
compartment. The CAB uses the wheel speed information from the wheel speed sensors to control
the ABS system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 4579
Electronic Brake Control Module: Service and Repair
1. Turn ignition Off. 2. Remove speed control servo. 3. Disconnect wiring harness 60-way
connector from anti-lock brake controller. 4. Remove controller mounting bolts, then the controller.
5. Reverse procedure to install. 6. Torque controller attaching bolts to 40 in. lbs. and electrical
connector screw to 105 in. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
The wheel speed sensors are located at each wheel and transmit wheel speed information to the
Controller Anti-Lock Brake.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Page 4583
Wheel Speed Sensor: Description and Operation
The wheel speed sensors are located at each wheel and transmit wheel speed information to the
Controller Anti-Lock Brake (CAB).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front
Wheel Speed Sensor: Service and Repair Front
Fig. 66 Front Speed Sensor Assembly
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove screw from clip
that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect
electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove
sensor head screw, then the sensor head from steering knuckle.
CAUTION: If sensor head is seized, use a punch and gently rock sensor back and forth until free.
Do not use pliers on sensor head.
5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and
Torque mounting bolt to 60 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 4586
Wheel Speed Sensor: Service and Repair Rear
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring
grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical
connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts,
then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head
from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and
forth until free. Do not use pliers on sensor head.
6. Reverse procedure to install. Torque sensor mounting bolt to 60 inch lbs. and U-bolt nuts to 65
ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding
Brake Bleeding: Service and Repair About Brake System Bleeding
WHEN BLEEDING BRAKES REMEMBER...
- Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender
covers to protect the vehicle's finish and electrical system.
- Always flush and bleed the brake hydraulic sys. when servicing the brakes, because:
Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake
fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which
may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits
and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of
the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should
be flushed.
- Never reuse brake fluid that has been drained from the brake system.
DOT 3,4 or DOT 5
As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type
fluid.
DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based.
DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a
dye).
DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if
all old fluid isn't removed when a system is refilled with silicone).
Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture
over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic
and won't damage paint like conventional brake fluid. It also has a higher boiling point.
Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve
brake systems in antique vehicles and those that sit for long periods of time between use.
Silicone also has slightly different physical properties and compressibility, making it unsuitable for
ABS systems calibrated to work with DOT 3 or 4 brake fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
About Brake System Bleeding > Page 4591
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
When bleeding ABS systems use only diaphragm type bleed pressure bleeder.
1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to
de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a
suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a
glass container partially filled with
clean brake fluid.
4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until
clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order.
6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure
bleeder from vehicle, ensure proper fluid level in master cylinder.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations
Brake Warning Indicator: Locations
Engine Compartment Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations
> Page 4595
Engine Compartment & Transaxle Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations
> Page 4596
Brake Warning Indicator: Description and Operation
The brake warning light is designed to light only when either: The parking brake is applied with the ignition key turned "ON".
- One of the two service brake systems has failed.
Bulb Check
The instrument panel bulb can be checked each time the ignition switch is turned to the start
position or the parking brake is set.
Pressure Differential Warning Light Switch
Purpose The function of the Pressure Differential Switch is to alert the driver to a malfunction in the
brake system.
Operation The hydraulic brake system is split diagonally. The left front and right rear brakes are
part of one system and the right front and left rear are part of another.
Both systems are routed through, but hydraulically separated by the Pressure Differential Switch.
If hydraulic pressure is lost in one system, the warning light switch will activate a red light on the
instrument panel, when the brake pedal is depressed. At this point the brakes require service.
- However, since the brake systems are split diagonally the vehicle will retain 50% of its stopping
capability in the event of a failure in either half.
The warning light switch is the latching type. It will automatically recenter itself after the repair is made and the brake pedal Is depressed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations
> Page 4597
Brake Warning Indicator: Testing and Inspection
Bulb Check
The instrument panel bulb can be checked each time the ignition switch is turned to the start
position or the parking brake is set.
Pressure Differential Warning Light Switch Circuit Check
1. Raise and support vehicle, then open a wheel cylinder bleeder valve. 2. Press down on brake
pedal and observe brake warning lamp. If lamp fails to illuminate, inspect for the following:
a. Faulty bulb. b. Disconnected electrical socket. c. A broken or disconnected wire at the switch,
located in the brake line "T" fitting, mounted on frame rail in engine compartment below master
cylinder.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications
Brake Caliper: Specifications
Caliper Bleed Screw 80-170 in.lb
Caliper Guide Pins 25-35 ft.lb
Caliper Adapter Mounting bolt 130-190 ft.lb
Caliper Bearing Retainer Mounting Bolt 200-300 in.lb
Brake Hoses to Calipers (Banjo Bolts) 19-29 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Diagrams > Kelsey-Hayes Double Pin Floating Caliper
Fig 2 Disc Brake Caliper
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Diagrams > Kelsey-Hayes Double Pin Floating Caliper > Page 4604
Single Pin Disc Brake Caliper
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Diagrams > Page 4605
Brake Caliper: Application and ID
Single Pin Disc Brake Caliper
Kelsey Hayes Single Pin Caliper
Fig 2 Disc Brake Caliper
Kelsey Hayes Double Pin Caliper
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Description and Operation > Kelsey-Hayes Double Pin Floating Caliper
Brake Caliper: Description and Operation Kelsey-Hayes Double Pin Floating Caliper
Fig 2 Disc Brake Caliper
Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly
The double pin caliper consists of a driving hub, braking disc, caliper, pads and adapter on vehicles
without an integral knuckle. The caliper is mounted through two bushings and sleeves. An
anti-rattle clip is attached to the outer pad and the inner pad has a retainer clip. The caliper is a one
piece casting with the inboard side containing a single piston and bore.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Description and Operation > Kelsey-Hayes Double Pin Floating Caliper > Page 4608
Brake Caliper: Description and Operation Kelsey-Hayes Single Piston Sliding Caliper
Disc Break Assembly
Caliper Mounting
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Description and Operation > Kelsey-Hayes Double Pin Floating Caliper > Page 4609
Single Pin Disc Brake Caliper
OPERATION
The single piston caliper assembly floats through a rubber bushing on a single pin threaded into the
adapter. The bushing is inserted into the inboard portion of the caliper.
Two machined abutments on the adapter position and align the caliper fore and aft. The guide pin
and bushing controls the movement of the caliper and the piston seal to assist in maintaining
proper shoe clearance.
All of the braking force is taken directly by the adapter. The caliper is a one-piece casting with the
inboard side containing a single piston cylinder bore.
CONSTRUCTION
Caliper Assembly Consists of a rotor, caliper, shoes and linings, and adapter.
Piston The phenolic piston is 2.13 inches in diameter.
Fig. 2 Piston Seal Function
Seal A square cut rubber piston seal is located in a machined groove in the caliper bore and
provides a seal between piston and caliper bore.
Boot A molded rubber dust boot installed in a groove in the cylinder bore and piston keeps
contamination from the caliper bore and piston. The boot mounts in the caliper bore and in a
groove in the piston.
Anti-Rattle Clips This assembly has three anti-rattle clips. One is on top of the inboard shoe, one
clip is on the bottom of the outboard shoe, and one clip is on top of the caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Description and Operation > Page 4610
Brake Caliper: Testing and Inspection
WITH CALIPER ON VEHICLE
Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any
ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper
assembly and install a new seal and boot, (and piston if corroded or scored).
Check the mating surfaces of the abutments on the caliper and adapter. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc.
Check the caliper dust boot and caliper pin bushings to determine if they are in good condition.
Replace if they are damaged, dry, or brittle.
WITH CALIPER REMOVED
Cleaning Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air.
Blow out all drilled passages and bores.
NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at
reassembly.
Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth.
- Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is
not increased more than 0.0254 mm (0.001 inch).
- If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or scored.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
Kelsey-Hayes Double Pin Caliper
For additional information see Removal Notes. See: Fundamentals and Basics
Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly
Fig 2 Disc Brake Caliper
NOTE: If a shoe and lining does not require replacement, reinstall, making sure each shoe is
returned to the original position.
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Remove caliper to knuckle attaching bolts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4613
Fig 3 Removing Caliper And Brake Shoes As An Assembly
4. Pull lower end of the caliper out from the machined abutment on the steering knuckle and roll
caliper out and away from braking disc. The shoe
assemblies will remain with the caliper.
Fig 4 Prying Outboard Shoe Assembly Away From Caliper
5. Remove outboard shoe by prying between shoe and caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4614
Fig 5 Removing Or Installing Inboard Shoe Assembly
6. Remove the inboard shoe from the assembly by pulling the shoe and lining assembly away from
the piston.
Kelsey-Hayes Single Pin Caliper
For additional information see Removal Notes. See: Fundamentals and Basics
Single Pin Disc Brake Caliper
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4615
Removing Or Installing Guide Pin
3. Remove caliper guide pin.
Loosening Caliper
4. After removing caliper guide pin, wedge the caliper away from the braking disc with a
screwdriver to break the gasket adhesive seals.
Removing Or Installing Caliper
5. Remove caliper from disc by slowly sliding caliper assembly out and away from braking disc.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4616
Hanging Caliper Out Of The Way
6. Support caliper firmly to prevent weight of caliper from damaging the flexible hose.
Removing Or Installing Outboard Shoe
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4617
Removing Or Installing Brake Disc
Removing Or Installing Inboard Shoe Assembly
7. Remove the outboard shoe assembly.
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
8. Mark disc and stud for assembly. 9. Remove braking disc from drive flange studs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4618
10. Remove the inboard shoe assembly.
Kelsey-Hayes Double Pin Caliper
For additional information see Installation Notes. See: Fundamentals and Basics
Fig 2 Disc Brake Caliper
1. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant Part Number
4318063, or equivalent.
Fig. 4 Brake Pad Identification
2. The inboard brake shoes are common. The outboard shoes are marked with an "L" or "R"
denoting which side of the vehicle they should be
installed on.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4619
Fig 5 Removing Or Installing Inboard Shoe Assembly
3. Install new inboard brake pad assembly in caliper, entering retainer into the bore in the piston.
Fig 7 Installing Outboard Shoe Assembly Onto Caliper
4. Remove protective paper from the noise suppression gasket and position the properly marked
outboard shoe hold-down spring onto caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4620
Fig 3 Removing Caliper And Brake Shoes As An Assembly
5. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. 6. Install attaching bolts and tighten to 24-34 Nm (18-25 ft lb).
CAUTION: When installing attaching bolts, use extreme caution not to cross the threads.
6. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are
torqued to half specification. THIS IS IMPORTANT.
Then repeat sequence to full specification.
7. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, be sure it has a firm pedal.
8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to
seat the linings. The vehicle may pull to one side or
the other if this is not done.
Kelsey-Hayes Single Pin Caliper
For additional information see Installation Notes. See: Fundamentals and Basics
Single Pin Disc Brake Caliper
1. Push piston back into cylinder bore with uniform pressure until it is bottomed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4621
Removing Or Installing Inboard Shoe Assembly
Removing Or Installing Brake Disc
2. Position inboard pad on adapter.
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
3. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4622
4. Clean both sides of braking disc with alcohol or suitable solvent.
Removing Or Installing Outboard Shoe
Removing Or Installing Caliper
5. While holding outboard pad in position on adapter, carefully position caliper over disc brake
rotor. 6. Lower caliper over rotor and adapter. 7. Install guide pin through bushing caliper and
adapter.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4623
Removing Or Installing Guide Pin
8. Press in on guide pin and thread pin into adapter. Torque pin to 25-35 ft lb. 9. Install wheel and
tire assembly, then lower vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4624
Brake Caliper: Service and Repair Disassembly and Assembly
Cleaning, Inspecting & Honing Caliper
Honing Brake Caliper Piston Bore
Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth.
- Bores that have deep scratches or scoring should be honed, using Tool C-4095, providing the
diameter of the bore is not increased more than 0.0254 mm (0.001 inch).
- If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or scored.
When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully
clean the seal and boot grooves with a stiff nonmetallic rotary brush.
Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the
caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time.
Be sure to install the hone baffle before honing bore. -
The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the
caliper after honing.
Kelsey-Hayes Single Pin Caliper
DISASSEMBLING CALIPER
1. Support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid
loss. 2. Place a small piece of wood between the piston and caliper fingers. 3. Carefully depress
brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has
passed bore opening). 4. Prop brake pedal to any position below the first inch of pedal travel -- to
prevent loss of brake fluid.
If both front caliper pistons are to be removed:
1. Disconnect flexible brake line at frame bracket after removing piston. 2. Plug brake tube and
remove piston from opposite caliper.
CAUTION: Under no condition should air pressure be used to remove piston from bore! Personal
Injury could result from such practice.
3. Disconnect brake flexible hose from the caliper. 4. To disassemble, mount caliper assembly in a
vise equipped with protective jaws.
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4625
Fig. 10 Dust Boot Removal
5. Support caliper and remove dust boot and discard.
Removing Piston Seal From Caliper
6. Using a plastic trim stick, work piston seal out of its groove in piston bore. Discard old seal. Do
not use a screwdriver or other metal tool for this
operation, because of possibility of scratching piston bore or burring edges of seal groove.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4626
Fig 11 Removing Bushings
7. Remove bushing from caliper by pressing out of bore, using a suitable tool. Discard bushing.
CLEANING AND INSPECTION
Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all
drilled passages and bores.
NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at
reassembly.
Honing Brake Caliper Piston Bore
Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth.
- Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is
not increased more than 0.0254 mm (0.001 inch).
- If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or scored.
When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully
clean the seal and boot grooves with a stiff nonmetallic rotary brush.
Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the
caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4627
ASSEMBLING CALIPER
1. Clamp caliper in vise (with protector jaws).
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
Installing New Piston Seal In Caliper
2. Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned
at one area in groove and gently worked around
the groove, using fingers until properly seated.
CAUTION: NEVER USE AN OLD PISTON SEAL. (Be sure that fingers are clean and seal is not
twisted or rolled).
3. Coat new piston boot with clean brake fluid leaving a generous amount inside of boot. 4. Position
dust boot over piston after coating with brake fluid.
Fig. 4 Caliper piston installation
5. Install piston into bore pushing it past the piston seal until it bottoms in the bore.
CAUTION: Force must be applied uniformly to avoid cocking the piston.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4628
6. Position dust boot in counterbore. Using a hammer and Tool C4842 with C4171 handle or
equivalent, drive boot into counterbore.
Fig 16 Installing Bushings
7. Compress flanges of guide pin bushings in with fingers and work into position by pressing IN on
bushings, using fingertips or plastic trim stick
until seated.
8. Be sure flanges extend over caliper casting evenly on both sides. 9. Before installing caliper
assembly on vehicle, inspect braking disc.
10. Install brake hose to caliper using new seal washers. 11. Bleed the brake system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Fundamentals and Basics > Removal Notes
Brake Caliper: Fundamentals and Basics Removal Notes
When Removing the Caliper, Remember...
- Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir
is only 1/3 full.
- Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender
covers to protect the vehicle's finish and electrical system.
- Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining
thickness between wheels on the same axle will result in a strong steering pull when the brakes are
applied.
- Work on one side at a time. If you forget how to reassemble the parts you can always use the
other side as a model.
- When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other
deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is
forced back into the caliper, these deposits will be forced back through the brake lines and into the
master-cylinder.
- When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake
fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to
"shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose
and a glass or plastic jar to catch the expelled fluid.
- Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses
can be damaged easily by this practice. These hoses are double walled, damage to the interior
pressure hose will not be visible.
- Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will
be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not
attempt to insert the piston back into the caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Fundamentals and Basics > Removal Notes > Page 4631
Brake Caliper: Fundamentals and Basics Installation Notes
WHEN INSTALLING CALIPERS AND PADS, REMEMBER...
- Clean and lubricate caliper slide joint/pins with high temperature silicone grease:
Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake
pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted
movement of the caliper slide assemblies to release the brakes.
If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon
the release of the brake pedal. This will result in overheated brakes and premature brake wear.
Disc Brake Mechanical Force Diagram
NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating
or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel
forces the inner pad against the rotor, then further travel forces the movable part of the caliper to
pull the outer pad against the rotor.
High temperature silicone lubricant must be used. Low temperature grease can melt and
contaminate the pads and rotors, or can bake into a very hard substance which binds the slides.
Petroleum based grease can cause the slide boots to soften and swell.
- Work on one side at a time. If you forget how to reassemble the parts you can always use the
other side as a model.
Anti-squeal Coating
- Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an
insulator to dampen high frequency vibrations that are generated during normal braking. These
compounds are highly effective in preventing brake squeal.
- Many professional repair shops recommend always rebuilding or replacing the calipers when
replacing the brake linings, because:
When the pistons are forced back into the calipers, the piston seals are dragged across any
corrosion or abrasives that may be deposited on the inside of the caliper.
Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston
is gradually withdrawn from the caliper. This results in the piston seals again being dragged across
the layer of corrosion and deposits.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Fundamentals and Basics > Removal Notes > Page 4632
Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking.
- Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck
bleeder screw is much easier with the caliper removed from the vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications
Brake Pad: Specifications
Minimum Combined Thickness Of Lining And Backing 0.313 in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Page 4636
Brake Pad: Service Precautions
Do not get any oil or grease on the linings.
It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is
worn or damaged.
Inspect and, if necessary, replace rear brake linings also.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Page 4637
Brake Pad: Application and ID
Single Pin Disc Brake Caliper
Kelsey Hayes Single Pin Caliper
Fig 2 Disc Brake Caliper
Kelsey Hayes Double Pin Caliper
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation
Brake Pad: Service and Repair Removal and Installation
Removal
For additional information see Removal Notes. See: Brake Caliper/Fundamentals and Basics
Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly
Fig 2 Disc Brake Caliper
NOTE: If a shoe and lining does not require replacement, reinstall, making sure each shoe is
returned to the original position.
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Remove caliper to knuckle attaching bolts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4640
Fig 3 Removing Caliper And Brake Shoes As An Assembly
4. Pull lower end of the caliper out from the machined abutment on the steering knuckle and roll
caliper out and away from braking disc. The shoe
assemblies will remain with the caliper.
Fig 4 Prying Outboard Shoe Assembly Away From Caliper
5. Remove outboard shoe by prying between shoe and caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4641
Fig 5 Removing Or Installing Inboard Shoe Assembly
6. Remove the inboard shoe from the assembly by pulling the shoe and lining assembly away from
the piston.
Installation
For additional information see Installation Notes. See: Brake Caliper/Fundamentals and Basics
Fig 2 Disc Brake Caliper
1. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant Part Number
4318063, or equivalent.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4642
Fig. 4 Brake Pad Identification
2. The inboard brake shoes are common. The outboard shoes are marked with an "L" or "R"
denoting which side of the vehicle they should be
installed on.
Fig 5 Removing Or Installing Inboard Shoe Assembly
3. Install new inboard brake pad assembly in caliper, entering retainer into the bore in the piston.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4643
Fig 7 Installing Outboard Shoe Assembly Onto Caliper
4. Remove protective paper from the noise suppression gasket and position the properly marked
outboard shoe hold-down spring onto caliper.
Fig 3 Removing Caliper And Brake Shoes As An Assembly
5. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. 6. Install attaching bolts and tighten to 24-34 Nm (18-25 ft lb).
CAUTION: When installing attaching bolts, use extreme caution not to cross the threads.
6. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are
torqued to half specification. THIS IS IMPORTANT.
Then repeat sequence to full specification.
7. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, be sure it has a firm pedal.
8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to
seat the linings. The vehicle may pull to one side or
the other if this is not done.
Removal
For additional information see Removal Notes. See: Brake Caliper/Fundamentals and Basics
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4644
Single Pin Disc Brake Caliper
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
Removing Or Installing Guide Pin
3. Remove caliper guide pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4645
Loosening Caliper
4. After removing caliper guide pin, wedge the caliper away from the braking disc with a
screwdriver to break the gasket adhesive seals.
Removing Or Installing Caliper
5. Remove caliper from disc by slowly sliding caliper assembly out and away from braking disc.
Hanging Caliper Out Of The Way
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4646
6. Support caliper firmly to prevent weight of caliper from damaging the flexible hose.
Removing Or Installing Outboard Shoe
Removing Or Installing Brake Disc
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4647
Removing Or Installing Inboard Shoe Assembly
7. Remove the outboard shoe assembly.
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
8. Mark disc and stud for assembly. 9. Remove braking disc from drive flange studs.
10. Remove the inboard shoe assembly.
Installation
For additional information see Installation Notes. See: Brake Caliper/Fundamentals and Basics
Single Pin Disc Brake Caliper
1. Push piston back into cylinder bore with uniform pressure until it is bottomed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4648
Removing Or Installing Inboard Shoe Assembly
Removing Or Installing Brake Disc
2. Position inboard pad on adapter.
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
3. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly. 4. Clean
both sides of braking disc with alcohol or suitable solvent.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4649
Removing Or Installing Outboard Shoe
Removing Or Installing Caliper
5. While holding outboard pad in position on adapter, carefully position caliper over disc brake
rotor. 6. Lower caliper over rotor and adapter. 7. Install guide pin through bushing caliper and
adapter.
Removing Or Installing Guide Pin
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4650
8. Press in on guide pin and thread pin into adapter. Torque pin to 25-35 ft lb. 9. Install wheel and
tire assembly, then lower vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Removal and Installation > Page 4651
Brake Pad: Service and Repair Cleaning and Inspection
Remove one of the front wheels and inspect the brake disc, caliper and linings. If linings are
contaminated replace them with fresh linings.
If a visual inspection does not adequately determine lining condition, remove the pads and
measure the total thickness of lining and backing at the thinnest point. If combined thickness of lining and backing is 7.95 mm (5/16 in) or less replace pads.
CAUTION: Do not get any oil or grease on the linings.
NOTES: The wheel bearings should be inspected at this time and repacked if necessary.
- It is recommended that all front wheel pads -- both sides -- be replaced whenever any front pad is
worn or damaged.
- Rear brake linings should be inspected when a brake problem is suspected.
- Uneven wear of linings on different sides of the caliper or vehicle may indicate a sticking caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications
Brake Rotor/Disc: Specifications
Nominal Thickness 0.870-0.861 in
Minimum Thickness 0.803 in
Total Indicated Runout (TIR) 0.005 in
Hub Runout 0.003 in
Thickness Variation (Maximum) 0.0005 in
Measured in 12 places 1" from edge of disc
Finish 15-80 micro-in
Fig 1 Checking Total Indicated Runout (TIR)
Fig 3 Checking Hub Runout
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4655
Fig 5 Checking Disc Thickness
Fig 7 Refacing Brake Disc -- Final Finish
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4656
Brake Rotor/Disc: Service Precautions
When machining brake discs it is essential to use precision equipment designed for this purpose to
insure proper brake operation.
Friction surfaces must have a non-directional, micro-inch finish to prevent brake roughness, avoid
pulls and erratic performance and promote long lining life and equal lining wear of both left and
right brakes.
Do not attempt to refinish brake rubbing surfaces unless equipment, capable of measuring in
micro-inches is available.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4657
Brake Rotor/Disc: Testing and Inspection
NOTE: If a vehicle has not been driven for a period of time, the discs will rust in the area not
covered by the lining and cause noise and chatter.
NOTE: Some discoloration or wear of the disc surface is normal and does not require re-surfacing
when linings are replaced.
CAUTION: Any servicing of the braking disc requires extreme care to maintain the braking disc
within service tolerances to ensure proper brake action.
BEFORE REFINISHING OR REFACING A BRAKING DISC INSPECT FOR:
- Scoring, rust, impregnation of lining material and worn ridges.
- Excessive wear and scoring of the disc
CAUTION: Excessive wear and scoring of the disc can cause temporary improper lining contact if
ridges are not removed before installation of new brake shoe assemblies.
- Runout or wobble
CAUTION: Excessive runout or wobble in a disc can increase pedal travel due, to piston knockback
This will increase guide pin bushing wear due to tendency of caliper to follow disc wobble.
- Thickness variation (Parallelism).
NOTE: Thickness variation in a disc can also result in pedal pulsation, chatter and surge due to
variation in brake output when disc section is uneven.
- Dishing or distortion (Flatness).
NOTE: Dishing or distortion can be caused by extreme heat and abuse of the brakes.
SPECIFICATION - See: Specifications
Fig 1 Checking Total Indicated Runout (TIR)
MEASURING TOTAL DISC RUNOUT ON VEHICLE:
NOTE: On Vehicle, Braking Disc (rotor) Runout is the combination of the individual runout of the
hub face and the runout of the disc. The hub and disc are separable.
NOTE: Before checking the runout, wheel bearings should be adjusted.
1. Remove the wheel and reinstall the lug nuts to tighten the disc to the hub. 2. Mount dial indicator
with adapter on steering arm with plunger contacting disc braking surface approximately one inch
from edge of disc. 3. Check lateral runout (both sides of disc).
- Runout should not exceed 0.13mm (0.005 inch).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4658
- If total runout is in exceeds specification check the lateral runout of the hub face.
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
MEASURING LATERAL RUNOUT OF THE HUB FACE:
1. Before removing disc, make a chalk mark across both the disc and one wheel stud, on the high
side of runout, so you'll know exactly how the disc
and hub was originally mounted.
2. Remove disc from hub.
Fig 3 Checking Hub Runout
3. Install dial indicator with adapter on steering arm with stem contacting hub face near outer
diameter (care must be taken to position dial indicator
stem outside the stud circle but inside the chamfer on the hub rim. Runout should not exceed
0.05mm (0.002 inch). If runout exceeds this specification, hub must be replaced.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4659
Fig 4 Indexing Disc And Wheel Stud
- If hub runout does not exceed this specification, install disc on hub with chalk marks 180 degrees
apart.
4. Finally, recheck runout of disc to see if runout is now within specifications.
- If runout is in excess of specifications, install a new disc or reface disc, being careful to remove as
little as possible from each side of disc. Remove equal amounts from each side of disc. Do not
reduce thickness below the recommended minimum thickness.
NOTE: Thickness variation measurements of disc should be made in conjunction with runout.
Fig 5 Checking Disc Thickness
THICKNESS VARIATION MEASUREMENTS
Measure thickness of disc at twelve (12) equal points with a micrometer at a radius approximately
25.4 mm (one (1) inch) from edge of disc. If thickness measurements vary by more than 13 mm (0.0005 inch) disc should be removed and
resurfaced, or a new disc installed.
- If cracks or burned spots are evident in the disc, disc must be replaced.
- For additional information on how to use a micrometer, see Fundamentals and Basics.See:
Fundamentals and Basics
NOTE: Light scoring and/or wear Is acceptable: If heavy scoring or warping is evident, the disc must be refinished or replaced.
- If cracks are evident in the disc, replace the disc.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Rotor Removal and Installation
Brake Rotor/Disc: Service and Repair Rotor Removal and Installation
Removal
1. Raise vehicle on hoist or jackstands. 2. Remove wheel and tire assembly.
Hanging Caliper Out Of The Way
3. Remove caliper assembly, but do not disconnect brake line. 4. Suspend caliper from wire hook
or loop to avoid strain on flexible hose.
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
5. Mark disc and stud for assembly. 6. Remove braking disc from drive flange studs.
Installation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Rotor Removal and Installation > Page 4662
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
1. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly. 2. Clean
both sides of braking disc with alcohol or suitable solvent. 3. Install caliper assembly.
For additional information see Installation Notes. See: Fundamentals and Basics
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Rotor Removal and Installation > Page 4663
Brake Rotor/Disc: Service and Repair Rotor Refinishing
CAUTION: When refacing a disc brake rotor the required 0.10 mm (0.004 inch) TIR (Total Indicator
Reading) and 0.013 mm (0.0005 in.) thickness variation limits MUST BE MAINTAINED. Extreme
care in the operation of rotor turning equipment is required.
Resurfacing Notes: This operation can be used when the disc surface is rusty or has lining
deposits. A sanding disc attachment will remove surface contamination without removing much material.
- It will generally follow variations in thickness which are in the disc.
Refacing Braking Disc Notes: Rotors do not have to be refaced whenever a disc brake is relined.
- If the rotor surface is deeply scored or warped or there is a complaint of brake roughness the rotor
should be refaced.
- The collets, shafts and adaptors on the lathe and the bearing cups in the rotor MUST be clean
and free from any chips or contamination.
- When mounting the disc on the lathe, strict attention to the manufacturer's instructions is required.
- If the disc is not mounted properly the run-out will be worse after refacing than before refacing.
Fig 6 Refacing Brake Disc
Fig 7 Refacing Brake Disc -- Final Finish
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Rotor Removal and Installation > Page 4664
- The use of a double straddle cutter which machines both sides of the disc at the same time is
highly recommended.
Fig 8 Minimum Disc Thickness Marking
Fig 8 Minimum Disc Thickness Marking
Measurements and specifications when servicing the braking disc:
NOTE: All braking discs (rotors) have markings for minimum allowable thickness cast on an
un-machined surface. This marking includes 0.76 mm (0.030 inch) allowable disc wear beyond the recommended 0.76
mm (0.030 inch) of disc refacing.
- This surface may be as shown, or on an alternate surface.
Do Not Reface Beyond ........................................................................................................................
....................................... 21.16 mm (0.833 in) Allows for Wear of 0.76mm (0.030 in.)
Minimum Allowable Thickness
................................................................................................................................................
20.4Omm (0.803 in)
NOTE: For additional information on how to use a micrometer, see Fundamentals and Basics. See:
Fundamentals and Basics
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Fundamentals and Basics > How to Use A Micrometer
Brake Rotor/Disc: Fundamentals and Basics How to Use A Micrometer
CONSTRUCTION
The spindle on a micrometer is moved in or out by rotating the thimble or ratchet.
The thread pitch on the spindle is 40 threads per inch. A single full rotation of the thimble extends
or retracts the spindle one thread or 1/40 of an inch (0.025, 25 thousands).
The thimble is divided into 25 equal divisions. Rotating the thimble one division will extend or
retract the spindle 1/25 of a thread.
(1/25) x (1/40)inch = 1/1000 inch (0.001), one division on the thimble is equal to 0.001 inches.
HOW TO READ
As the thimble is rotated out it uncovers a scale on the sleeve. Each major division on the scale is
1/10 of an inch (0.100)
Each major division is separated into 4 minor divisions, each equal to 25/1000 of an inch (0.025).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Fundamentals and Basics > How to Use A Micrometer > Page 4667
A full rotation will move the thimble exactly one minor division on the sleeve.
To read the micrometer you must add the measurement which is visible on the sleeve to the
measurement which is showing on the thimble
In the example the sleeve measurement is 0.250 inches and the thimble measurement is 0.017
inches. The total measurement is then equal to the two measurements combined, 0.267 inches.
NOTES
The accuracy and calibration of a micrometer can be altered easily by applying too much pressure
to the spindle. Use the thimble to quickly rotate the spindle in until it is near the rotor.
- Use the ratchet to rotate the spindle into contact with the rotor.
- The ratchet has a built in slip which prevents excessive stress or pressure from developing.
Calibrate the micrometer regularly. Most micrometers come with a precision dowel which allows for
easy and accurate adjustments.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Fundamentals and Basics > How to Use A Micrometer > Page 4668
Brake Rotor/Disc: Fundamentals and Basics Installation Notes
WHEN INSTALLING A ROTOR/DISC, REMEMBER...
Thoroughly clean the rotors with brake cleaner.
- Any grease or brake fluid which comes in contact with the rotor should be thoroughly cleaned
prior to installing the new pads/linings.
- Grease and other contaminants become lodged in the microscopic pores of the rotor's surface.
This prolongs the brake-in time of the new linings and contaminates the friction material.
- Commercially produced aerosol brake cleaners should be used to clean the rotor. Unlike
carburetor cleaner or other petroleum based solvents, brake cleaner does not leave a residue on
the rotor's surface.
Recheck the wheel bearings once the tires are installed.
- With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt
to rock them back and forth. There should be no detectable lateral (wobble) movement.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Fundamentals and Basics > How to Use A Micrometer > Page 4669
Brake Rotor/Disc: Fundamentals and Basics Tightening Notes
WHEN TIGHTENING LUG NUTS, REMEMBER...
Always tighten the lug nuts to the correct torque specification. Lightly lubricate the studs with an
anti-seize compound to ensure proper torque and prevent damage to the threads. Tighten in an
alternating pattern around the wheel until the wheel is centered on the studs. Do your final
tightening with a torque wrench. When servicing disc brakes it is very important to properly torque
the wheel assembly.
Lug nuts which are installed with an air impact tool are often over-torqued. This may distort the
rotor and result in excessive lateral runout (rotor wobble) and a pedal pulsation upon braking.
Recheck the wheel bearings once the tires are installed. With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to
rock them back and forth. There should be no detectable lateral (wobble) movement.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Specifications
Backing Plate: Specifications
Brake support plate to rear axle bolts
............................................................................................................................................... 88-129
Nm (65-95 ft lb)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Specifications > Page 4674
Backing Plate: Testing and Inspection
Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and
cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate
exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and
excessive rust, indicating need for replacement.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Specifications > Page 4675
Backing Plate: Service and Repair
Fig 9 Removing Brake Cable From Backing Plate
REMOVAL
1. With wheel and brake drum removed, remove brake shoe assemblies and disconnect brake
cable from parking brake lever. 2. Using a suitable tool such as an aircraft type hose clamp
compress the flared legs of cable retainer and pull brake cable out of support plate. 3. Disconnect
hydraulic brake tube from wheel cylinder. 4. Remove support to wheel cylinder attaching nuts and
washers. 5. Remove brake support and spindle mounting screws. 6. Remove brake support,
spindle and gasket from rear axle.
Fig 1 Rear Wheel Brake
INSTALLATION
1. Install support plate, spindle and gasket to rear axle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Specifications > Page 4676
Brake Shoe Contact Pads On Backing (Support) Plate
2. Apply RTV sealant around wheel cylinder mounting surface. 3. Install wheel cylinder and attach
hydraulic brake tube. 4. Insert parking brake cable into support plate and attach cable to parking
brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and wheel. Adjust and
bleed brakes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Testing and Inspection
Brake Drum: Testing and Inspection
Fig 5 Drum Maximum Diameter Specification
NOTE: Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking, or
showing taper should also be machined, removing only enough stock to true up the brake drum.
If the braking surface diameter is within specifications: Drums should be cleaned and inspected for
cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced.
- Minor scores should be removed with sandpaper.
- Grooves and large scores can only be removed by machining with special equipment, as long as
the braking surface is within specifications stamped on brake drum outer surface.
Measuring Drum Runout and Diameter
NOTE: Measure the drum runout and diameter with an accurate gauge.
Maximum Variation There should be no variation in the drum diameter greater than 0.O5mm (0.002
in.).
Maximum Runout Drum runout should not exceed 0.15mm (0.006 in.) out of round. -
If the drum runout or diameter variation exceed these values the drum should be refaced.
Maximum Single Cut For best results in eliminating the irregularities that cause brake roughness
and surge, the amount of material removed during a single cut should be limited to 0.13mm (0.005
in.).
Final Cut When the entire braking surface has been cleaned a final cut of 0.0254mm (0.001 in.) will
assure a good drum surface providing the equipment used is capable of giving the precision
required for resurfacing brake drums. Deeper cuts are permissible for the sole purpose of removing deep score marks.
CAUTION: Do not reface more than 1.52mm (0.60 in.) over the standard drum diameter.
NOTE: If one brake drum is machined, the other should also be machined to the same diameter to
maintain equal braking forces.
After a brake drum is machined: Wipe the braking surface diameter with a cloth soaked in
denatured alcohol.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal
Brake Drum: Service and Repair Brake Drum Removal
For additional information see Notes, Warnings, and Hints.
Fig. 9 Release Brake Adjuster
Fig. 6 Release type brake adjuster
1. Remove the tire and wheel assembly. 2. Remove rear plug from brake adjusting access hole. 3.
Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of
adjusting screw. 4. Insert Tool C-3784 or equivalent, into brake adjusting hole and engage notches
of brake adjusting screw. Release brake by prying down with
adjusting tool.
NOTE: The rear hubs are held on by the axle nut which should be covered by a dust cap.
Fig. 3 Wheel bearing assembly
5. Remove rear hub and drum assembly. 6. Inspect brake lining for wear, shoe alignment, or
contamination from grease or brake fluid. Inspect wheel bearings for rust or signs of wear.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal > Page 4682
Brake Drum: Service and Repair Brake Drum Installation
For additional information see Notes, Warnings, and Hints.
NOTE: Reinstallation of retaining clips is not necessary.
Fig. 3 Wheel bearing assembly
1. Install hub and drum assembly.
- Torque adjusting nut to 270 inch lbs. while rotating wheel. - Stop wheel and loosen adjusting nut. Tighten adjusting nut finger tight. End play should be 0.0001---0.0020 inch. - Install castle lock with
slots aligned with cotter pin hole. - Install cotter pin and grease cap.
2. Install wheel and tire assembly.
- When tightening wheel stud nuts, using a criss-cross tightening sequence as shown.
- Tighten all stud nuts to one-half specified torque. Repeat, fully tightening to specified torque.
Fig 6 Wheel Stud Tightening Sequence
- Wheel stud lug nut torque 110 - 135 Nm (85 - 115 ft lb)
3. Adjust rear brakes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal > Page 4683
Brake Drum: Service and Repair Brake Drum Refinishing
Fig 5 Drum Maximum Diameter Specification
CAUTION: Do not reface more than 1.52mm (0.60 in.) over the standard drum diameter.
NOTE: If one brake drum is machined, the other should also be machined to the same diameter to
maintain equal braking forces.
NOTE: All drums will show markings of maximum allowable diameter. For example, a drum will
have a marking of MAX. Dia. 231.0mm (9.09 in.). This marking includes 0.76mm (0.030 in.) for
allowable drum wear beyond the recommended 1.52mm (0.060 in.) of drum refacing.
Measuring Drum Runout and Diameter
NOTE: Measure the drum runout and diameter with an accurate gauge.
Maximum Variation There should be no variation in the drum diameter greater than 0.O5mm (0.002
in.).
Maximum Runout Drum runout should not exceed 0.15mm (0.006 in.) out of round. If the drum runout or diameter variation exceed these values the drum should be refaced.
Maximum Single Cut For best results in eliminating the irregularities that cause brake roughness
and surge, the amount of material removed during a single cut should be limited to 0.13mm (0.005
in.).
Final Cut When the entire braking surface has been cleaned a final cut of 0.0254mm (0.001 in.) will
assure a good drum surface providing the equipment used is capable of giving the precision
required for resurfacing brake drums. Deeper cuts are permissible for the sole purpose of removing deep score marks.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Adjustments
Brake Shoe: Adjustments
Fig. 9 Release Brake Adjuster
Fig. 6 Release type brake adjuster
NOTE: Normally self adjusting drum brakes will not require manual adjustment but in the event of a
brake reline it is advisable to make the initial adjustment manually to speed up the adjusting time.
1. Jack up vehicle so all wheels are free to turn. 2. Remove rear adjusting hole cover from brake
supports of vehicle. 3. Be sure parking brake lever is fully released, then back off parking brake
cable adjustment so there is slack In cable. 4. Insert adjusting tool C-3784 or equivalent, into star
wheel of adjusting screw. Move handle of tool upward until a slight drag is felt when road
wheel is rotated.
5. Insert a thin screwdriver or piece of welding rod into brake adjusting hole and push adjusting
lever out of engagement with star wheel.
CAUTION: Care should be taken so as not to bend adjusting lever or distort lever spring.
6. While holding adjusting lever out of engagement, back off star wheel to insure a free wheel with
no brake shoe drag. 7. Repeat above adjustment at the other rear wheel. Install adjusting hole
covers in brake supports. 8. Adjust parking brake after wheel brake adjustment.
CAUTION: It is important to follow the above sequence to avoid the possibility of the parking brake
system causing brake drag, if the parking brakes are adjusted before the service brakes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation
Brake Shoe: Service and Repair Brake Shoe Removal and Installation
Removal
For additional information see Notes, Warnings, and Hints.
Fig 1 Rear Wheel Brake
Fig 2 Removing And Installing Shoe Return Springs
TIP: Unless you are very familiar with this rear brake system you should consider servicing one
side at a time. This will leave you an example of how the pieces go back together.
1. Remove rear wheel, and hub and drum assembly. 2. Using tool C-3785 or equivalent, remove
brake shoe return springs.
NOTE: For additional information see Brake Spring Removal and Installation Notes.
NOTE: The secondary shoe return spring overlaps the primary shoe return spring.
3. Slide the eye of automatic adjuster cable off anchor and then unhook from adjusting lever. 4.
Remove cable, overload spring, cable guide and anchor plate. 5. Disengage adjusting lever from
spring by sliding forward to clear pivot, then working out from under spring.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4689
6. Remove spring from pivot. 7. Remove shoe to shoe spring from secondary shoe web and
disengage form primary shoe web. 8. Remove spring. 9. Disengage primary and secondary shoes
and remove adjusting star wheel assembly from shoes.
Fig 3 Removing And Installing Shoe Retainers, Springs And Nails
10. Remove brake shoe retainers, springs and nails using Tool C-4070 or equivalent and remove
from support. 11. Remove parking brake lever from secondary shoe. 12. Remove shoes. 13.
Disengage parking brake lever from the parking brake cable.
Installation
For additional information see Notes, Warnings, and Hints.
Fig 1 Rear Wheel Brake
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4690
Brake Shoe Contact Pads On Backing (Support) Plate
NOTE: Lubricate the six shoe tab contact pads on support plate with a thin film of MOPAR MultiPurpose Lubricant, Part number 2932524 or equivalent.
Fig 3 Removing And Installing Shoe Retainers, Springs And Nails
1. Slide primary shoe against support plate, at the same time engage shoe web with wheel cylinder
piston and against anchor. Using tool C-4070 or
equivalent install shoe retaining nail, retainer, and spring.
NOTE: For additional information see Brake Spring Removal and Installation Notes.
Fig 7 Removing Of Installing Parking Brake Strut And Spring
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4691
2. Install anchor plate over anchor, then install eye of adjuster cable over anchor.
Fig 2 Removing And Installing Shoe Return Springs
3. Engage primary shoe return spring in web of shoe and install free end over anchor. 4. Slide
parking brake strut into slot in parking brake lever. Slide anti-rattle spring over free end of strut. 5.
Engage parking brake lever with cable. Install parking brake lever into rectangular hole of
secondary brake shoe.
Installing Brake Shoes
6. Slide secondary shoe into position and engage with wheel cylinder piston and free end of strut.
Install shoe retaining nail, retainer, and spring. 7. Insert protruding hole rim of cable guide into hole
in secondary shoe web. Holding guide in position, engage secondary shoe return spring through
both, hole in guide, and hole in web. Using Tool C-3785, install spring over anchor. Be sure cable guide remains flat against shoe web and that secondary spring overlaps primary).
- Using pliers, squeeze ends of spring loops (around anchor) until parallel.
8. Install adjusting star wheel assembly between primary and secondary shoes, with star wheel
next to secondary shoe.
- The left star wheel adjusting stud end is stamped "L" (indicating its position on the vehicle) and
the star wheel is cadmium plated.
- The right star wheel is black and the adjusting stud end is stamped "R". Install shoe to shoe
spring between shoes.
- Engage primary shoe first.
9. Install adjusting lever spring over pivot pin on shoe web. Install adjusting lever under spring and
over pivot pin. Slide lever slightly rearward to
lock in position.
10. Thread adjuster cable over guide and hook end of overload spring in lever.
- Be sure eye of cable is pulled tight against anchor and in a straight line with guide.
11. Check operation of automatic application adjuster by pulling adjuster cable rearward. Star
wheel should rotate upwards.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4692
Brake Shoe: Service and Repair Cleaning and Inspection
Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of
the above conditions exists, brake linings should be replaced. Do not attempt to replace only one
set of brake shoes; they should be replaced as an axle set only to maintain equal braking forces.
Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a
slight blue color. If any component exhibits signs of overheating, replace hold-down and return
springs with new ones. Overheated springs lose their pull and could cause brake linings to wear
out prematurely. Inspect all springs for sags, bends and external damage, and replace as
necessary.
Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above conditions
exist, replace retainers and pins.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Specifications > Bore Diameter
Wheel Cylinder: Specifications
Rear Wheel Cylinder Bore Diameter 0.75 in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Specifications > Bore Diameter > Page 4697
Wheel Cylinder: Specifications
Hydraulic Brake Tubes To All Fittings (if Not Specified) 115-170 in.lb
Wheel Cylinder To Rear Brake Support Plate 75 in.lb
Wheel Cylinder Bleed Screw 60-100 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Specifications > Page 4698
Fig 3 Wheel Cylinder
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal
Wheel Cylinder: Service and Repair Wheel Cylinder Removal
Fig 1 Brake Tube Disconnected
1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid). 2.
Disconnect brake tube from wheel cylinder.
Fig 2 Removing Or Installing Wheel Cylinder
3. Remove wheel cylinder attaching bolts, then pull wheel cylinder assembly out of support.
For additional information see Notes, Warnings, and Hints.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 4701
Wheel Cylinder: Service and Repair Wheel Cylinder Installation
For additional information see Notes, Warinings, and Hints.
Brake Shoe Contact Pads On Backing (Support) Plate
1. Apply RTV sealant around wheel cylinder mounting surface.
Fig 2 Removing Or Installing Wheel Cylinder
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 4702
Fig 1 Brake Tube Disconnected
2. Slide wheel cylinder into position on support. Install mounting screws and tighten as specified. 3.
Connect brake tube to wheel cylinder. 4. Insert parking brake cable into support plate and attach
cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and
wheel. 7. Adjust and bleed brakes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 4703
Wheel Cylinder: Service and Repair Cleaning and Inspection
Fig 3 Wheel Cylinder
1. With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak.
2. Block brake pedal in stroke position, visually check the boots for cuts, tears, or heat cracks.
If any of the above conditions exist, the wheel cylinders should be completely cleaned, inspected
and new parts installed.
NOTE: A slight amount of fluid on the boot may be preservative fluid used at assembly and should
not automatically be considered a leak.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 4704
Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul
For additional information see Notes, Warinings, and Hints.
Fig 3 Wheel Cylinder
NOTE: To perform service operations or inspections of the wheel cylinders, it will be necessary to
remove the cylinders from the support plate and disassemble on the bench.
CAUTION: Wheel cylinders with cup expanders must have cup expanders after any service
procedures (reconditioning or replacement).
DISASSEMBLING WHEEL CYLINDERS
1. Pry boots away from cylinders and remove. 2. Press In on one piston to force out other piston,
cup, spring -- with cup expanders -- cup and piston. 3. Wash wheel cylinder, pistons, and spring in
clean brake fluid or alcohol.
- Clean thoroughly and blow dry with compressed air.
CAUTION: Do not use a rag as lint from the rag will adhere to bore surfaces.
4. Inspect cylinder bore and piston for scoring and pitting.
- Wheel cylinder bores and pistons that are badly scored or pitted should be replaced.
- Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with
crocus cloth, using a circular motion.
- Black stains on the cylinder walls are caused by piston cups and will not impair operation of
cylinder.
ASSEMBLING WHEEL CYLINDERS
Assembly Notes: Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid.
- If the boots are deteriorated, cracked or do not fit tightly on the push rods or the cylinder casting,
install new boots.
1. Coat cylinder bore with clean brake fluid. 2. Install expansion spring with cup expanders in
cylinder. Install cups in each end of cylinder with open end of cups facing each other. 3. Install
piston in each end of cylinder having the flat face of each piston contacting the flat face of each
cup, already installed. 4. Install a boot over each end of cylinder. Use care not to damage boot.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding
Brake Bleeding: Service and Repair About Brake System Bleeding
WHEN BLEEDING BRAKES REMEMBER...
- Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender
covers to protect the vehicle's finish and electrical system.
- Always flush and bleed the brake hydraulic sys. when servicing the brakes, because:
Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake
fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which
may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits
and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of
the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should
be flushed.
- Never reuse brake fluid that has been drained from the brake system.
DOT 3,4 or DOT 5
As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type
fluid.
DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based.
DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a
dye).
DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if
all old fluid isn't removed when a system is refilled with silicone).
Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture
over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic
and won't damage paint like conventional brake fluid. It also has a higher boiling point.
Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve
brake systems in antique vehicles and those that sit for long periods of time between use.
Silicone also has slightly different physical properties and compressibility, making it unsuitable for
ABS systems calibrated to work with DOT 3 or 4 brake fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > About Brake System Bleeding > Page 4710
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
When bleeding ABS systems use only diaphragm type bleed pressure bleeder.
1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to
de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a
suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a
glass container partially filled with
clean brake fluid.
4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until
clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order.
6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure
bleeder from vehicle, ensure proper fluid level in master cylinder.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications
Brake Caliper: Specifications
Caliper Bleed Screw 80-170 in.lb
Caliper Guide Pins 25-35 ft.lb
Caliper Adapter Mounting bolt 130-190 ft.lb
Caliper Bearing Retainer Mounting Bolt 200-300 in.lb
Brake Hoses to Calipers (Banjo Bolts) 19-29 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Diagrams > Kelsey-Hayes Double Pin Floating Caliper
Fig 2 Disc Brake Caliper
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Diagrams > Kelsey-Hayes Double Pin Floating Caliper > Page 4716
Single Pin Disc Brake Caliper
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Diagrams > Page 4717
Brake Caliper: Application and ID
Single Pin Disc Brake Caliper
Kelsey Hayes Single Pin Caliper
Fig 2 Disc Brake Caliper
Kelsey Hayes Double Pin Caliper
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper
Brake Caliper: Description and Operation Kelsey-Hayes Double Pin Floating Caliper
Fig 2 Disc Brake Caliper
Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly
The double pin caliper consists of a driving hub, braking disc, caliper, pads and adapter on vehicles
without an integral knuckle. The caliper is mounted through two bushings and sleeves. An
anti-rattle clip is attached to the outer pad and the inner pad has a retainer clip. The caliper is a one
piece casting with the inboard side containing a single piston and bore.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper > Page 4720
Brake Caliper: Description and Operation Kelsey-Hayes Single Piston Sliding Caliper
Disc Break Assembly
Caliper Mounting
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper > Page 4721
Single Pin Disc Brake Caliper
OPERATION
The single piston caliper assembly floats through a rubber bushing on a single pin threaded into the
adapter. The bushing is inserted into the inboard portion of the caliper.
Two machined abutments on the adapter position and align the caliper fore and aft. The guide pin
and bushing controls the movement of the caliper and the piston seal to assist in maintaining
proper shoe clearance.
All of the braking force is taken directly by the adapter. The caliper is a one-piece casting with the
inboard side containing a single piston cylinder bore.
CONSTRUCTION
Caliper Assembly Consists of a rotor, caliper, shoes and linings, and adapter.
Piston The phenolic piston is 2.13 inches in diameter.
Fig. 2 Piston Seal Function
Seal A square cut rubber piston seal is located in a machined groove in the caliper bore and
provides a seal between piston and caliper bore.
Boot A molded rubber dust boot installed in a groove in the cylinder bore and piston keeps
contamination from the caliper bore and piston. The boot mounts in the caliper bore and in a
groove in the piston.
Anti-Rattle Clips This assembly has three anti-rattle clips. One is on top of the inboard shoe, one
clip is on the bottom of the outboard shoe, and one clip is on top of the caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Description and Operation > Page 4722
Brake Caliper: Testing and Inspection
WITH CALIPER ON VEHICLE
Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any
ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper
assembly and install a new seal and boot, (and piston if corroded or scored).
Check the mating surfaces of the abutments on the caliper and adapter. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc.
Check the caliper dust boot and caliper pin bushings to determine if they are in good condition.
Replace if they are damaged, dry, or brittle.
WITH CALIPER REMOVED
Cleaning Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air.
Blow out all drilled passages and bores.
NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at
reassembly.
Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth.
- Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is
not increased more than 0.0254 mm (0.001 inch).
- If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or scored.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
Kelsey-Hayes Double Pin Caliper
For additional information see Removal Notes. See: Fundamentals and Basics
Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly
Fig 2 Disc Brake Caliper
NOTE: If a shoe and lining does not require replacement, reinstall, making sure each shoe is
returned to the original position.
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Remove caliper to knuckle attaching bolts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4725
Fig 3 Removing Caliper And Brake Shoes As An Assembly
4. Pull lower end of the caliper out from the machined abutment on the steering knuckle and roll
caliper out and away from braking disc. The shoe
assemblies will remain with the caliper.
Fig 4 Prying Outboard Shoe Assembly Away From Caliper
5. Remove outboard shoe by prying between shoe and caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4726
Fig 5 Removing Or Installing Inboard Shoe Assembly
6. Remove the inboard shoe from the assembly by pulling the shoe and lining assembly away from
the piston.
Kelsey-Hayes Single Pin Caliper
For additional information see Removal Notes. See: Fundamentals and Basics
Single Pin Disc Brake Caliper
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4727
Removing Or Installing Guide Pin
3. Remove caliper guide pin.
Loosening Caliper
4. After removing caliper guide pin, wedge the caliper away from the braking disc with a
screwdriver to break the gasket adhesive seals.
Removing Or Installing Caliper
5. Remove caliper from disc by slowly sliding caliper assembly out and away from braking disc.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4728
Hanging Caliper Out Of The Way
6. Support caliper firmly to prevent weight of caliper from damaging the flexible hose.
Removing Or Installing Outboard Shoe
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4729
Removing Or Installing Brake Disc
Removing Or Installing Inboard Shoe Assembly
7. Remove the outboard shoe assembly.
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
8. Mark disc and stud for assembly. 9. Remove braking disc from drive flange studs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4730
10. Remove the inboard shoe assembly.
Kelsey-Hayes Double Pin Caliper
For additional information see Installation Notes. See: Fundamentals and Basics
Fig 2 Disc Brake Caliper
1. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant Part Number
4318063, or equivalent.
Fig. 4 Brake Pad Identification
2. The inboard brake shoes are common. The outboard shoes are marked with an "L" or "R"
denoting which side of the vehicle they should be
installed on.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4731
Fig 5 Removing Or Installing Inboard Shoe Assembly
3. Install new inboard brake pad assembly in caliper, entering retainer into the bore in the piston.
Fig 7 Installing Outboard Shoe Assembly Onto Caliper
4. Remove protective paper from the noise suppression gasket and position the properly marked
outboard shoe hold-down spring onto caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4732
Fig 3 Removing Caliper And Brake Shoes As An Assembly
5. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment
on knuckle assembly. 6. Install attaching bolts and tighten to 24-34 Nm (18-25 ft lb).
CAUTION: When installing attaching bolts, use extreme caution not to cross the threads.
6. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are
torqued to half specification. THIS IS IMPORTANT.
Then repeat sequence to full specification.
7. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, be sure it has a firm pedal.
8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to
seat the linings. The vehicle may pull to one side or
the other if this is not done.
Kelsey-Hayes Single Pin Caliper
For additional information see Installation Notes. See: Fundamentals and Basics
Single Pin Disc Brake Caliper
1. Push piston back into cylinder bore with uniform pressure until it is bottomed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4733
Removing Or Installing Inboard Shoe Assembly
Removing Or Installing Brake Disc
2. Position inboard pad on adapter.
Fig 2 Marking Brake Disc And Wheel Stud For Reassembly
3. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4734
4. Clean both sides of braking disc with alcohol or suitable solvent.
Removing Or Installing Outboard Shoe
Removing Or Installing Caliper
5. While holding outboard pad in position on adapter, carefully position caliper over disc brake
rotor. 6. Lower caliper over rotor and adapter. 7. Install guide pin through bushing caliper and
adapter.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4735
Removing Or Installing Guide Pin
8. Press in on guide pin and thread pin into adapter. Torque pin to 25-35 ft lb. 9. Install wheel and
tire assembly, then lower vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4736
Brake Caliper: Service and Repair Disassembly and Assembly
Cleaning, Inspecting & Honing Caliper
Honing Brake Caliper Piston Bore
Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth.
- Bores that have deep scratches or scoring should be honed, using Tool C-4095, providing the
diameter of the bore is not increased more than 0.0254 mm (0.001 inch).
- If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or scored.
When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully
clean the seal and boot grooves with a stiff nonmetallic rotary brush.
Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the
caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time.
Be sure to install the hone baffle before honing bore. -
The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the
caliper after honing.
Kelsey-Hayes Single Pin Caliper
DISASSEMBLING CALIPER
1. Support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid
loss. 2. Place a small piece of wood between the piston and caliper fingers. 3. Carefully depress
brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has
passed bore opening). 4. Prop brake pedal to any position below the first inch of pedal travel -- to
prevent loss of brake fluid.
If both front caliper pistons are to be removed:
1. Disconnect flexible brake line at frame bracket after removing piston. 2. Plug brake tube and
remove piston from opposite caliper.
CAUTION: Under no condition should air pressure be used to remove piston from bore! Personal
Injury could result from such practice.
3. Disconnect brake flexible hose from the caliper. 4. To disassemble, mount caliper assembly in a
vise equipped with protective jaws.
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4737
Fig. 10 Dust Boot Removal
5. Support caliper and remove dust boot and discard.
Removing Piston Seal From Caliper
6. Using a plastic trim stick, work piston seal out of its groove in piston bore. Discard old seal. Do
not use a screwdriver or other metal tool for this
operation, because of possibility of scratching piston bore or burring edges of seal groove.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4738
Fig 11 Removing Bushings
7. Remove bushing from caliper by pressing out of bore, using a suitable tool. Discard bushing.
CLEANING AND INSPECTION
Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all
drilled passages and bores.
NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at
reassembly.
Honing Brake Caliper Piston Bore
Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth.
- Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is
not increased more than 0.0254 mm (0.001 inch).
- If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or scored.
When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully
clean the seal and boot grooves with a stiff nonmetallic rotary brush.
Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the
caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4739
ASSEMBLING CALIPER
1. Clamp caliper in vise (with protector jaws).
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
Installing New Piston Seal In Caliper
2. Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned
at one area in groove and gently worked around
the groove, using fingers until properly seated.
CAUTION: NEVER USE AN OLD PISTON SEAL. (Be sure that fingers are clean and seal is not
twisted or rolled).
3. Coat new piston boot with clean brake fluid leaving a generous amount inside of boot. 4. Position
dust boot over piston after coating with brake fluid.
Fig. 4 Caliper piston installation
5. Install piston into bore pushing it past the piston seal until it bottoms in the bore.
CAUTION: Force must be applied uniformly to avoid cocking the piston.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4740
6. Position dust boot in counterbore. Using a hammer and Tool C4842 with C4171 handle or
equivalent, drive boot into counterbore.
Fig 16 Installing Bushings
7. Compress flanges of guide pin bushings in with fingers and work into position by pressing IN on
bushings, using fingertips or plastic trim stick
until seated.
8. Be sure flanges extend over caliper casting evenly on both sides. 9. Before installing caliper
assembly on vehicle, inspect braking disc.
10. Install brake hose to caliper using new seal washers. 11. Bleed the brake system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Fundamentals and Basics > Removal Notes
Brake Caliper: Fundamentals and Basics Removal Notes
When Removing the Caliper, Remember...
- Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir
is only 1/3 full.
- Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender
covers to protect the vehicle's finish and electrical system.
- Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining
thickness between wheels on the same axle will result in a strong steering pull when the brakes are
applied.
- Work on one side at a time. If you forget how to reassemble the parts you can always use the
other side as a model.
- When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other
deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is
forced back into the caliper, these deposits will be forced back through the brake lines and into the
master-cylinder.
- When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake
fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to
"shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose
and a glass or plastic jar to catch the expelled fluid.
- Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses
can be damaged easily by this practice. These hoses are double walled, damage to the interior
pressure hose will not be visible.
- Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will
be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not
attempt to insert the piston back into the caliper.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Fundamentals and Basics > Removal Notes > Page 4743
Brake Caliper: Fundamentals and Basics Installation Notes
WHEN INSTALLING CALIPERS AND PADS, REMEMBER...
- Clean and lubricate caliper slide joint/pins with high temperature silicone grease:
Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake
pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted
movement of the caliper slide assemblies to release the brakes.
If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon
the release of the brake pedal. This will result in overheated brakes and premature brake wear.
Disc Brake Mechanical Force Diagram
NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating
or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel
forces the inner pad against the rotor, then further travel forces the movable part of the caliper to
pull the outer pad against the rotor.
High temperature silicone lubricant must be used. Low temperature grease can melt and
contaminate the pads and rotors, or can bake into a very hard substance which binds the slides.
Petroleum based grease can cause the slide boots to soften and swell.
- Work on one side at a time. If you forget how to reassemble the parts you can always use the
other side as a model.
Anti-squeal Coating
- Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an
insulator to dampen high frequency vibrations that are generated during normal braking. These
compounds are highly effective in preventing brake squeal.
- Many professional repair shops recommend always rebuilding or replacing the calipers when
replacing the brake linings, because:
When the pistons are forced back into the calipers, the piston seals are dragged across any
corrosion or abrasives that may be deposited on the inside of the caliper.
Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston
is gradually withdrawn from the caliper. This results in the piston seals again being dragged across
the layer of corrosion and deposits.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Fundamentals and Basics > Removal Notes > Page 4744
Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking.
- Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck
bleeder screw is much easier with the caliper removed from the vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications
Brake Fluid: Specifications
Use new brake fluid only, to top off the master cylinder or refill system. Never use reclaimed fluid,
unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid
from a container that has been left open.
Brake Fluid Type DOT 3
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 4748
Brake Fluid: Testing and Inspection
Indications of fluid contamination: Swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid.
To test for contamination: Put small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil contamination.
If contaminated: Drain and thoroughly flush system, and replace all rubber parts.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 4749
Brake Fluid: Service and Repair
Aluminum Master Cylinder
NOTES:
- Check master cylinder fluid level twice annually.
- Master cylinder reservoirs are marked with the words "fill to bottom of rings".
- Add DOT 3 fluid to bring the level to the bottom of the primary split ring.
CAUTION: Use of brake fluid with a lower boiling point than DOT 3 fluid could result in brake failure
during long, hard braking.
CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in
this manner will absorb moisture which could result in brake failure during long, hard braking.
CAUTION: Use of petroleum based fluids will result in seal damage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator >
Component Information > Service and Repair > Depressurizing Hydraulic Accumulator
Brake Fluid Accumulator: Service and Repair Depressurizing Hydraulic Accumulator
NOTE:The ABS pump/motor assembly will keep the hydraulic accumulator charged to a pressure
between 1600-2000 psi anytime the ignition is in the ON position. The pump/motor cannot run if the
ignition is off or either battery cable is disconnected.
WARNING: The hydraulic accumulator should be depressurized before disassembling any portion
of the hydraulic system.
1. Turn ignition switch to the OFF position, or disconnect battery ground cable. 2. Pump brake
pedal a minimum of 40 times using approximately 50 pounds of pedal force. Pedal feel should
change noticeably when accumulator is
discharged.
3. After a definite increase in pedal effort is felt, pump pedal a few additional times. This will
remove all hydraulic pressure from the system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator >
Component Information > Service and Repair > Depressurizing Hydraulic Accumulator > Page 4754
Brake Fluid Accumulator: Service and Repair Accumulator Replacement
1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair."
See: Depressurizing Hydraulic Accumulator
WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or
damage to painted surfaces.
2. Remove accumulator assembly. 3. Reverse procedure to install. Torque accumulator to 30 ft.
lbs., then turn ignition On and check for leaks.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure
Sensor/Switch > Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
Engine Compartment Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure
Sensor/Switch > Component Information > Locations > Page 4758
Engine Compartment & Transaxle Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure
Sensor/Switch > Component Information > Locations > Page 4759
Brake Fluid Pressure Sensor/Switch: Description and Operation
The switch activates a light on the dash panel to indicate that one of the hydraulic systems has
failed. There are two basic types of switches. In some earlier models, as pressure falls in one
system, the normal pressure of the other system forces the piston to the inoperative side where it
contacts the switch terminal, causing the warning lights to illuminate.
On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one
side of the system, the piston in the valve is forced toward the failed side where it latches in
position and illuminates the warning light.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications
Brake Hose/Line: Specifications
Hydraulic brake tubes to all fittings (if not specified)
.................................................................................................................... 13-20 Nm (115-170 in lb)
Brake hoses to calipers (banjo bolts)
.................................................................................................................................................. 26-40
Nm (19-29 ft lb) Front Brake hose intermediate bracket
.............................................................................................................................................. 8-13 Nm
(75-115 in lb)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Page 4763
Brake Hose/Line: Service and Repair
- Always use factory recommended brake hose to insure quality, correct length and superior fatigue
life.
- Care should be taken to make sure that the tube and hose mating surfaces are clean and free
from nicks and burrs. Right and left hoses are not interchangeable.
- Use new copper seal washers on all "banjo" bolts and tighten all fittings to specified torque.
Connections should be tight and properly made.
- The flexible hydraulic brake hose should always be installed on the vehicle by first attaching the
"Banjo" connector to the caliper assembly. Then bolt the intermediate hose bracket to the strut
assembly allowing the bracket to position the hose to prevent twisting. Attach the hose to the body
bracket and steel brake tubing. Tighten all fittings to specified torque.
- The body bracket and hose end are "keyed" so that they will only fit one way.
- Install rear brake hoses first to the trailing arm cross member tubes and then to the floor pan
tubes. Minimize hose twisting.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation
Brake Proportioning/Combination Valve: Description and Operation
Some vehicles incorporate a hold-off valve, usually in combination with the brake warning switch.
This valve holds off hydraulic pressure to the front disc brakes to a given psi range to allow the rear
drum brake shoes to overcome the return springs and begin to contact drums. This action helps
prevent locking of the front brakes on icy surfaces under light braking conditions. This valve has no
effect on front brake pressure during hard stopping.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Page 4767
Brake Proportioning/Combination Valve: Service and Repair
The proportioning valves should never be disassembled.
1. Remove fresh air intake ducts and air cleaner assembly. 2. Remove pressure and return hose
from hydraulic unit. 3. Remove brake tube and fitting from proportioning valve. 4. Remove
proportioning valve from hydraulic assembly. 5. Reverse procedure to install, noting the following:
a. Torque proportioning valve bolts to 30 ft. lbs. b. Torque brake tube to 11 ft. lbs. c. Bleed brake
system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Diagrams
Height Sensing Proportioning Valve
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Diagrams > Page 4771
Load Compensator: Description and Operation
Height Sensing Proportioning Valve
CAUTION: The use of aftermarket load leveling or capacity increasing devices is prohibited. Use of
air shock absorbers or helper springs will cause the valve to inappropriately reduce the rear brake
power potentially resulting in increased stopping distance.
PURPOSE
Proportioning valves balance front to rear braking by controlling at a given ratio, the increase in
rear system hydraulic pressure above a preset level. Under light pedal application, the valve allows
full hydraulic pressure to the rear brakes.
OPERATION
These vehicles use a height sensing dual proportioning valve in addition to the regular differential
warning switch. This valve is located under the load bed just forward of the rear axle. The height
sensing rear brake proportioning valve automatically provides optimum brake balance front-to-rear
regardless of the vehicle load condition. The valve modulates the pressure to the rear brakes
sensing vehicle load condition through relative movement between the rear axle and the load floor.
The valve is mounted to a load floor cross member. A large external spring is connected between a
lever mounted on the valve and an adjustable bracket mounted on the rear axle. In conditions of
light load the line pressure to the rear brakes is minimized. As the load increases (resulting in
decreasing vehicle height) higher brake line pressure is allowed.
The proportioning valve section operates by transmitting full input pressure to the rear brakes up to
a certain point, called the split point, and beyond that point it reduces the amount of pressure
increase to the rear brakes according to a certain ratio.
Thus, on light pedal applications, approximately equal brake pressure will be transmitted to the
front and rear brakes, while at higher pressures, the pressure transmitted to the rear brakes will be
lower than to the front brakes to prevent premature rear wheel lock-up and skid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Diagrams > Page 4772
Load Compensator: Testing and Inspection
Rear Brakes Locking On Application
Height Sensing Proportioning Valve
Fig. 3 Master cylinder & brake warning switch.
Symptom When a premature rear wheel slide is obtained on brake application, it could be an
indication that the fluid pressure to the rear brakes is above the reduction ratio for the rear line
pressure and that a malfunction has occurred within the proportioning valve unit which should be
tested.
To test the proportioning valve, proceed as follows:
1. Disconnect the external spring at the valve end. 2. Install one gauge and "T" of set C4007-A or
equivalent in the line from either master cylinder port to the brake valve assembly. 3. Install the
second gauge to either rear brake outlet port between proportioning valve assembly and the rear
brake line. 4. Bleed both hydraulic circuits and the gauges. 5. Have a helper exert pressure on the
brake pedal (holding pressure) to get a reading on the valve inlet gauge and check the reading on
the outlet
gauge. The inlet pressure should be 500 psi and the outlet pressure should be 100-200 psi.
- If not, replace the valve torque mounting bolts to 250 inch lbs.
- If the valve tests OK re-adjust external spring and road test vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Diagrams > Page 4773
Load Compensator: Adjustments
Height Sensing Proportioning Valve
NOTE: After installing a new height sensing dual proportioning valve, bleed both hydraulic circuits
at rear brakes.
CAUTION: The rubber stone/snow shield must be installed when ever the valve is serviced. The
shield protects the valve and hydraulic lines from stone impact and the packing of snow and slush.
1. Lift vehicle with a frame contact hoist or other means so that rear suspension is hanging free
with shock absorbers disconnected from the axle. 2. Remove tire and wheels from rear axle. 3.
Loosen both front spring hanger pivot bolts.
NOTE: Ensure rear springs do not contact hoist, or the adjustment will not be correct.
4. Loosen adjustment nut on the actuator assembly. 5. Verify actuator assembly hook is properly
seated on valve lever. 6. Pull actuator assembly toward spring hanger until valve lever bottoms on
valve body. Hold in position and torque adjustment nut to 25 inch lbs (5
Nm).
7. Install shocks and tire and wheel assemblies, then lower vehicle. 8. With full weight on vehicles
wheels, torque both front spring hanger pivot bolts to 95 ft lb (129 Nm). 9. Road test vehicle.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications
Brake Master Cylinder: Specifications
Hydraulic brake tubes to all fittings (if not specified)
.................................................................................................................... 13-20 Nm (115-170 in lb)
Master cylinder to brake booster mounting nuts
......................................................................................................................... 22.6-34 Nm (200-300
in lb) Brake booster assembly to dash panel
........................................................................................................................................ 22.6-34 Nm
(200-300 in lb)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > Page 4777
Brake Master Cylinder: Service Precautions
CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Description and Operation > With Antilock Brakes
Brake Master Cylinder: Description and Operation With Antilock Brakes
This Anti-lock Brake System (ABS) uses an integral hydraulic assembly which contains the wheel
circuit valves used for brake pressure modulation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Description and Operation > With Antilock Brakes > Page 4780
Brake Master Cylinder: Description and Operation Without Antilock Brakes
Aluminum Master Cylinder
CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface.
OPERATION
The brake system is a diagonally split system.
This system operates on the same principles as conventional front and rear split systems using
primary and secondary master cylinders moving simultaneously to exert hydraulic pressure on their
respective systems.
The hydraulic brake lines on this system, however, have been diagonally split front to rear (left front
to right rear and right front to left rear) in place of separate lines to the front and rear wheels.
System Failure In the event of a system failure this would cause the remaining good system to do
all the braking on one front wheel and the opposite rear wheel, thus maintaining 50% of the total
braking force.
The hydraulic pressure loss would result in a pressure differential in the system and cause a
warning light on the dashboard to glow as in front and rear split systems.
CONSTRUCTION
The tandem master cylinder has a glass reinforced nylon reservoir and an anodized aluminum
body.
The secondary outlet tube from the master cylinder is connected to the valve mounted under the
master cylinder. The front part of this block supplies the right rear and left front brakes.
- The rear portion of the block connects to the primary outlet tube and supplies the right front and
left rear brakes.
The reservoir is indexed to prevent installation in the wrong direction.
The cap diaphragms are slit to allow pressure to equalize.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Description and Operation > Page 4781
Brake Master Cylinder: Testing and Inspection
INSPECTION
Inspect for Leakage
NOTE: The master-cylinder should be cleaned thoroughly prior to inspection (several days
preferably). Spilled brake fluid can be easily confused with leakage.
Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the
outside of the brake booster.
- Inspect for signs of seepage or bubbled paint on the brake booster.
- If any leakage is detected the master-cylinder should be replaced or overhauled
Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the
master-cylinder for leakage.
- If the fittings are leaking they should be disassembled and inspected.
Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking.
Overhaul or replace the master-cylinder if any leakage is indicated.
Inspect for Oil Contamination.
- Inspect the rubber gasket on the inside of the master-cylinder lid. If the gasket is swollen or
bloated, the brake fluid is contaminated with oil.
- Siphon or scoop a small amount of brake fluid out of the master-cylinder and place into a
styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil
contaminants will float on the surface and dissolve the styrofoam.
NOTE: If any oil contamination is present ALL brake components containing rubber seals will need
to be replaced or overhauled. This includes the master-cylinder, both front calipers, both rear wheel
cylinders, and all flexible brake hoses.
Verify Hold-Down Bolts Are Tight
- While someone is applying and releasing pressure to the brake pedal, verify the the
master-cylinder is tightly secured to the brake booster.
Retighten hold-down bolts if necessary.
Functional Checks
WARNING: Always bleed the entire brake system and verify the rear brakes are properly adjusted
prior to diagnosing a master-cylinder as defective. For additional information on master-cylinder /
brake pedal relationship see Fundamentals and Basics. See: Fundamentals and Basics
Check Related Systems Check for proper brake booster operation 1. With the engine "OFF", depress and release the brake
pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal
firmly and start the engine.
If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does
not go down slightly the brake booster is not assisting in brake operation and should be diagnosed
for problems.
- Check and adjust rear brakes.
- Check all brake lines and brake assemblies for leakage.
Repair all deficiencies with related systems prior to diagnosing the master-cylinder as defective.
Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Description and Operation > Page 4782
Pedal Reserve Checks
- The pedal should be firm and not leak down.
Prior to replacing a master-cylinder for poor pedal travel or feel verify the following: There were no problems with any of the related systems.
- The entire brake system has been bled.
- Rear brakes are properly adjusted.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Description and Operation > Page 4783
Brake Master Cylinder: Adjustments
Not adjustable
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding
Brake Master Cylinder: Service and Repair Master Cylinder Bleeding
Bench Bleeding
Bleeding Master Cylinder
NOTE: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder if
the master cylinder has been bench bled and refilled prior to installation.
1. Clamp master cylinder in vise and attach bleeding tubes. 2. Use residual valve on outlet of each
bleeder tube. 3. Fill both reservoirs with approved brake fluid. 4. Depress push rod slowly and then
allow pistons to return. 5. Repeat several times until all air bubbles are expelled. 6. Remove
bleeding tubes from cylinder, plug outlets and install caps. 7. Remove from vise and install master
cylinder.
For additional information see Bench Bleeding Notes. See: Fundamentals and Basics
Pressure Bleeding
Air Trapped In Brake System
NOTE: When bleeding the brake system some air may be trapped in the brake line or valving far
upstream, sometimes as much as ten feet from the bleeder screw. Therefore it is absolutely
essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure
the system is purged of all air bubbles.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4786
Bleeding Brake System
Caliper Bleeding Screw
CAUTION: Pressure bleed system using equipment designed for this purpose and vehicle only.
1. Wipe master cylinder caps and top with a clean rag. 2. Connect pressure bleeder following
manufacturer's instructions for use of bleeder. 3. Attach a clear plastic hose to the bleeder screw at
one wheel and insert the other end of the tube into a clear jar containing fresh brake fluid. 4. Open
the bleeder screw at least one full turn.
CAUTION: "Cracking" the bleeder screw often allows only a slow weak fluid flow. This may not be
sufficient to remove all air from the system.
5. After a good volume of fluid has been forced through the brake system, an "air free flow" in the
plastic hose and clear jar indicates a thorough
bleed.
6. Repeat this procedure at all other bleeder screws. 7. Check brake pedal travel. If pedal travel is
excessive repeat the procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4787
Brake Master Cylinder: Service and Repair Master Cylinder Replacement
Removal
Master Cylinder
1. Disconnect primary and secondary brake tubes from master cylinder and install plugs at outlets.
2. Remove nuts attaching master cylinder to power brake booster. 3. Slide master cylinder straight
out, away from power brake booster.
For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics
Installation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4788
Master Cylinder
1. Position master cylinder over studs of power brake booster. 2. Align push rod with master
cylinder piston. 3. Install attaching nuts and tighten to specification 22.6-34 Nm (200-300 in lb). 4.
Connect brake tubes and have a helper apply force to the brake pedal while tube nuts are cracked
to release any air, then tighten to specification
13-20 Nm (115-170 in lb).
For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4789
Brake Master Cylinder: Service and Repair Master Cylinder Overhaul
Aluminum Master Cylinder
CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface.
If the cylinder is scored, replace the master cylinder as an assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4790
Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement
Removing Reservoir
1. Clean housing and reservoir. 2. Remove caps and empty brake fluid. 3. Position master cylinder
in vise. 4. Rock reservoir from side to side and remove from master cylinder housing.
CAUTION: Do not pry off with tool as this may damage reservoir.
Removing Grommets
5. Remove housing to reservoir grommets. 6. Install new housing to reservoir grommets in master
cylinder housing. 7. Lubricate reservoir mounting area with brake fluid. 8. Place reservoir in position
over grommets and seat reservoir with a rocking motion onto master cylinder housing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4791
Brake Master Cylinder: Service and Repair Hydraulic Assembly Replacement
1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair."
See: Brake Fluid Accumulator/Service and
Repair/Depressurizing Hydraulic Accumulator
WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or
damage to painted surfaces.
2. Remove fresh air intake and air cleaner assembly from engine. 3. Remove windshield washer
fluid reservoir, then disconnect electrical connectors from hydraulic assembly. 4. Drain as much
fluid from hydraulic reservoir as possible. 5. Disconnect pump high pressure line from hydraulic
unit. 6. Disconnect pump return hose from steel tube, then cap the end of the steel tube. 7.
Disconnect all brakes tubes from hydraulic assembly. 8. Remove retainer clip from brake pedal pin.
9. Remove four hydraulic mounting unit nuts, then the hydraulic unit.
10. Reverse procedure to install, noting the following:
a. Torque mounting bolts to 250 inch lbs. b. Lubricate bearing surface of pedal pin with lubriplate. c.
Install new retainer clip on pedal pin. d. Torque brake tubes to hydraulic unit to 30 ft. lbs. e. Torque
return hose clamp to 10 inch lbs. f.
Torque high pressure hose to 145 inch lbs.
g. Bleed brake system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Page 4792
Brake Master Cylinder: Tools and Equipment
BASIC SERVICE (Removal and Installation)
- Fender cover (servicing and bleeding a master-cylinder can be a messy process)
WARNING: DOT 3 or 4 brake fluid is very corrosive to the vehicles finish and electrical
connections.
- Drip pan. - Complete set of combination wrenches or sockets. - Bleeding device:
- Pressure bleeder or
- Vacuum bleeder or
- One-man brake bleeder kit or
- Length of clear plastic hose (3/16 inch ID) and a glass jar.
Brake Bleeding Setup
- Brake adjusting tool (rear brake adjustment should be checked) - Clean shop towels.
OPTIONAL
- Master Cylinder bleeding kit (contains plastic fittings and hoses used for bleeding master
cylinders) - Suction bulb (for removing brake fluid from reservoir)
IF MASTER-CYLINDER IS OVERHAULED
- Snap-ring pliers - Small pry bar (for separating the reservoir from the cylinder) - Feeler gauges
(for checking piston to cylinder clearance).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints
Brake Master Cylinder: Fundamentals and Basics Notes, Warnings, and Hints
REMOVAL
WARNING: DOT 3 or DOT 4 brake fluid is very corrosive to your vehicles finish.
Removing master cylinders can be a messy process. To prevent or minimize any possible damage
perform the following: Siphon all brake fluid from the master-cylinder reservoir prior to removal.
- Use a fender cover to protect the vehicles finish.
- Use a drip pan to catch all fluid that leaks from the master-cylinder during removal.
- Any brake fluid which contacts the vehicles finish should be washed off immediately.
- Any brake fluid which drips onto electrical connections should be immediately removed (aerosol
brake cleaner works well for this).
After the brake lines have been disconnected from the master-cylinder place vacuum caps over
ends of the lines to prevent further leakage or contamination.
Once the master-cylinder has been removed place it in a drip pan. Although the reservoir is empty,
brake fluid trapped within the cylinder bore will continue to slowly leak out.
OVERHAUL
WARNING: Never hone aluminum cylinders, if deposits cannot be removed with crocus cloth the
cylinder should be replaced.
Check the cylinder bore for excessive clearance. With the piston installed you should not be able to
install a 0.006 inch feeler gauge between piston and cylinder. If the clearance is greater than 0.006
inches the cylinder should be replaced.
When installing the piston and seals into the cylinder always use clean brake fluid or assembly
lubricant to lubricate the components.
INSTALLATION
Prior to installation the master-cylinder should be bench bled (this can be done on the vehicle but it
is much easier on a workbench.
NOTE: Normal brake bleeding procedures will not remove air which is trapped in the cylinder bore
area of a master-cylinder.
Attach the brake line fittings prior to snugging down the master-cylinder retaining bolts. The fittings
are much easier to start turning when the master-cylinder is still loose.
WARNING: Remember to tighten the retaining bolts after the brake lines are installed and
tightened.
When snugging down the retaining bolts, alternately tighten them in small increments. This
prevents the master-cylinder or push rod from becoming cocked.
Upon installing the master-cylinder the entire brake system (front and rear) will need to be bled. Air
enters the brake system as soon as the brake lines are removed. It only requires a very small
amount of air in the system to create a soft brake pedal.
WARNING: Never test drive a vehicle after a master-cylinder replacement until a firm brake pedal
with a 75% reserve is established.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 4795
Brake Master Cylinder: Fundamentals and Basics Parts Reminder List
RECOMMENDED PARTS
Basic Service, Replacement New or rebuilt master-cylinder
- Fresh/New brake fluid
If Overhaul is Required Master cylinder overhaul kit
- Brake assembly lubricant
Optional Aerosol brake cleaner.
New or Rebuilt Master Cylinder Always closely compare the new master-cylinder with the old master-cylinder. Minor variations in
the size and depth of the primary piston can result in significant reductions in braking performance.
Examine the end of the master-cylinder where the pushrod contacts the piston. The depth and
diameters of the pistons should match.
Brake Fluid
- Proper bench bleeding the master-cylinder and flushing the brake system will require a minimum
of 16 oz of brake fluid.
- Never Mix DOT 3 (light amber in color) with DOT 5 (purple in color). There have been reports of
damage to brake system seals when DOT 3 and DOT 5 fluids are mixed
- Always store brake fluid in a sealed container. When left open brake fluid will absorb moisture
from the air. This reduces the boiling point of the brake fluid and could lead to a soft pedal or brake
system failure during prolonged or emergency braking.
- Never add automatic transmission fluid, engine oil, or power steering fluid to the master-cylinder.
Petroleum based fluids will cause the rubber seals and gaskets in the brake system to swell and
leak.
Master Cylinder Overhaul Kit Overhaul kits will often come with a variety cup and seal sizes. Closely match the old cups and
seals with the new ones.
Brake Assembly Lubricant Assembly lubricant can greatly simply the master-cylinder overhaul process and prolong the life of
the new seals.
- Clean brake fluid can be used to lubricate the master-cylinder bore during assembly but assembly
lube is much slicker and prevents any sticking or binding and possible damage to the new cups
and seals.
Aerosol Brake Cleaner -
Commercially produced aerosol brake cleaners are designed to effectively clean brake systems
while not leaving an oily residue.
- Do not use carburetor cleaner or solvent based products to clean brake system components.
These products will leave a residue which could contaminate the brake fluid or cause a reduction in
braking performance.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 4796
Brake Master Cylinder: Fundamentals and Basics Master Cylinder / Brake Pedal Relationship
MASTER CYLINDER / BRAKE PEDAL RELATIONSHIP
WARNING: Master Cylinders can be easily misdiagnosed for problems related to excessive brake
pedal travel.
Excessive brake pedal travel is often associated with a defective master-cylinder, however total
pedal travel is affected by a wide variety of components and issues.
Issues Affecting Pedal Travel
Brake Fluid
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 4797
- Brake fluid which is contaminated with air or water will significantly add to the amount of pedal
travel.
- Pure DOT 3 (or 4) brake fluid is incompressible (allowing for a solid, firm pedal). A small amount
of air trapped in the brake fluid will require extra effort from the master-cylinder to compress it,
resulting in a soft and spongy pedal.
- During prolonged or severe braking the brake fluid temperature can rapidly rise above 212
degrees F. When this occurs any water in the brake fluid will boil into steam (which is
compressable) and create a soft and spongy pedal.
Rear Brake Shoe Adjustment Drum brake system utilize return springs to pull the shoes away from the drums when not in use.
The amount of distance the shoes have to extend to meet the drums greatly affects the amount of
pedal travel.
- Shoes/Linings which are badly out of adjustment can by themselves result in a brake pedal
sinking all the way to the floor
NOTE: Improperly adjusted rear shoes/linings also affect the parking brake.
Calipers Excessive rotor wobble caused by a warped rotor or loose/worn wheel bearings can knock the
caliper piston further inward from its normal resting position. This results in additional pedal travel
required to extend the piston and apply the brakes.
Drum Expansion Drums which are worn past their "Discard" thickness are prone to expanding outwards into an oval
shape during heavy braking. This drum expansion results in additional brake pedal travel.
Brake Fade During prolonged or severe braking, the amount of pedal effort/travel required to slow the vehicle
increases as the ability of the brakes to dissipate heat decreases.
- As the brake linings heat up, their "coefficient of friction" is reduced (they become slicker). As the
coefficient of friction is reduced, more hydraulic pressure is required to stop the vehicle. More
hydraulic pressure results in more heat which then results in more pedal fade.
- As the brake linings, rotors, and drums begin to wear, their ability to absorb and release heat is
reduced significantly. This makes worn brakes more prone to "pedal fade".
NOTE: Prior to replacing a master-cylinder, verify the entire brake system is functioning properly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 4798
Brake Master Cylinder: Fundamentals and Basics Bench Bleeding Notes
BENCH BLEEDING
Why
A master-cylinder will develop little or no pressure if air is trapped in cylinder bore. Normal brake
bleeding will not remove air trapped within the master-cylinder.
How
Clamp the master-cylinder securely in a vice. It is usually best to clamp the side of the vice onto the
flat surface that is used to secure the master-cylinder to the brake booster.
There are two basic methods for bleeding master-cylinder, one utilizes stroking the master-cylinder
to expel air from the cylinder bore while the other utilizes a large syringe to backflush fluid from the
outlet ports to the reservoir.
Stroking Fill the master-cylinder with clean brake fluid.
- The brake line fittings on the master-cylinder should be capped or plugged.
NOTE: Special "bench bleeding" plastic fittings are available which allow for recirculating the brake
fluid back into the reservoir.
- Using a dull object, slowly stroke the master-cylinder piston, air and brake fluid will be expelled
from the brake line fittings. Prior to releasing the piston plug or cap the outlet ports.
- Repeat this procedure 8-10 times or until no air is emitted from the outlet ports.
- When finished, cap the outlet ports and install the master-cylinder.
Syringe Fill the syringe (one especially designed for brake bleeding) with clean brake fluid.
- Insert the end of the syringe into one of the outlet ports on the master-cylinder.
- Slowly compress the syringe and back flush the brake fluid through the master-cylinder.
- A combination of air and brake fluid will be emitted from the inlet port in the fluid reservoir.
- Repeat this procedure until only brake fluid is emitted into the reservoir.
- Cap the outlet ports and install the master-cylinder.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Bore Diameter
Wheel Cylinder: Specifications
Rear Wheel Cylinder Bore Diameter 0.75 in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Bore Diameter > Page 4803
Wheel Cylinder: Specifications
Hydraulic Brake Tubes To All Fittings (if Not Specified) 115-170 in.lb
Wheel Cylinder To Rear Brake Support Plate 75 in.lb
Wheel Cylinder Bleed Screw 60-100 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Page 4804
Fig 3 Wheel Cylinder
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal
Wheel Cylinder: Service and Repair Wheel Cylinder Removal
Fig 1 Brake Tube Disconnected
1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid). 2.
Disconnect brake tube from wheel cylinder.
Fig 2 Removing Or Installing Wheel Cylinder
3. Remove wheel cylinder attaching bolts, then pull wheel cylinder assembly out of support.
For additional information see Notes, Warnings, and Hints.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 4807
Wheel Cylinder: Service and Repair Wheel Cylinder Installation
For additional information see Notes, Warinings, and Hints.
Brake Shoe Contact Pads On Backing (Support) Plate
1. Apply RTV sealant around wheel cylinder mounting surface.
Fig 2 Removing Or Installing Wheel Cylinder
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 4808
Fig 1 Brake Tube Disconnected
2. Slide wheel cylinder into position on support. Install mounting screws and tighten as specified. 3.
Connect brake tube to wheel cylinder. 4. Insert parking brake cable into support plate and attach
cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and
wheel. 7. Adjust and bleed brakes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 4809
Wheel Cylinder: Service and Repair Cleaning and Inspection
Fig 3 Wheel Cylinder
1. With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak.
2. Block brake pedal in stroke position, visually check the boots for cuts, tears, or heat cracks.
If any of the above conditions exist, the wheel cylinders should be completely cleaned, inspected
and new parts installed.
NOTE: A slight amount of fluid on the boot may be preservative fluid used at assembly and should
not automatically be considered a leak.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal > Page 4810
Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul
For additional information see Notes, Warinings, and Hints.
Fig 3 Wheel Cylinder
NOTE: To perform service operations or inspections of the wheel cylinders, it will be necessary to
remove the cylinders from the support plate and disassemble on the bench.
CAUTION: Wheel cylinders with cup expanders must have cup expanders after any service
procedures (reconditioning or replacement).
DISASSEMBLING WHEEL CYLINDERS
1. Pry boots away from cylinders and remove. 2. Press In on one piston to force out other piston,
cup, spring -- with cup expanders -- cup and piston. 3. Wash wheel cylinder, pistons, and spring in
clean brake fluid or alcohol.
- Clean thoroughly and blow dry with compressed air.
CAUTION: Do not use a rag as lint from the rag will adhere to bore surfaces.
4. Inspect cylinder bore and piston for scoring and pitting.
- Wheel cylinder bores and pistons that are badly scored or pitted should be replaced.
- Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with
crocus cloth, using a circular motion.
- Black stains on the cylinder walls are caused by piston cups and will not impair operation of
cylinder.
ASSEMBLING WHEEL CYLINDERS
Assembly Notes: Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid.
- If the boots are deteriorated, cracked or do not fit tightly on the push rods or the cylinder casting,
install new boots.
1. Coat cylinder bore with clean brake fluid. 2. Install expansion spring with cup expanders in
cylinder. Install cups in each end of cylinder with open end of cups facing each other. 3. Install
piston in each end of cylinder having the flat face of each piston contacting the flat face of each
cup, already installed. 4. Install a boot over each end of cylinder. Use care not to damage boot.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Diagrams
Parking Brake Cable Routing
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Diagrams > Page 4815
Parking Brake Cable: Testing and Inspection
Inspect parking brake cable ends, inspect cables for kinks, fraying and elongation, and replace as
necessary.
TIP: Use a small hose clamp to compress clamp where it enters backing plate to remove.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement
Parking Brake Cable: Service and Repair Front Cable Replacement
REMOVING PARKING BRAKE FRONT CABLE
Parking Brake Cable Routing
1. Loosen cable adjusting nut under car and disengage front cable from connector.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4818
2. Loosen cable housing retainers at the rail bracket and parking brake pedal assembly. 3. Lift floor
mat for access to floor pan and force seal out of hole. 4. Pull cable end forward and disconnect
from clevis. 5. Pull cable assembly through hole. INSTALLING PARKING BRAKE FRONT CABLE
Parking Brake Pedal
1. Feed cable assembly through hole in floor and attach to brake pedal assembly. 2. Engage cable
end in lever clevis. 3. Install floor pan seal and floor mat. 4. Feed cable assembly through rail
bracket and fasten with retainer. 5. Engage cable end into connector on intermediate cable
assembly. 6. Adjust service and parking brakes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4819
Parking Brake Cable: Service and Repair Rear Cable Replacement
REMOVING PARKING BRAKE REAR CABLE
Parking Brake Cable Routing
1. The independent rear brake cables are attached to rear connectors.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4820
2. Should it become necessary to remove either parking brake cable for installation of a new cable,
proceed as follows:
3. With vehicle jacked up on a suitable hoist, remove wheel and tire.
Removing Brake Cable From Support Plate
4. Back off cable adjusting nut to provide slack and disconnect rear brake cable from connector.
Remove retaining clip from brake cable bracket.
Remove brake drum from spindle. Disconnect cable from parking brake lever. Using an aircraft
type hose clamp and screwdriver, compress retainers on end of cable housing and start housing
out of support plate. Remove clamp when retainer is free.
5. Pull out brake cable assembly from support plate and disconnect from bracket under spring.
INSTALLING PARKING BRAKE REAR CABLE
1. Insert brake cable and housing into brake support plate making certain that housing retainers
lock the housing firmly into place.
2. Attach brake cable to parking lever.
3. Install brake drum and wheel.
4. Attach cable assembly to bracket under spring seat.
5. Insert brake cable and housing through cable bracket and install retaining clip.
6. Insert brake cable into connector.
7. Adjust service brakes and then parking brakes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
I/P, Cowl & Steering Column Components
LH Kickpanel On Park Brake Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications
Vacuum Brake Booster: Specifications
Master cylinder to brake booster mounting nuts
......................................................................................................................... 22.6-34 Nm (200-300
in lb) Brake booster assembly to dash panel
........................................................................................................................................ 22.6-34 Nm
(200-300 in lb)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 4828
Vacuum Brake Booster: Description and Operation
These units are self contained vacuum hydraulic power braking units. They are the vacuum
suspended type which use engine intake manifold vacuum and atmospheric pressure for their
power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, integral
with the vacuum power diaphragms, controls degree of brake application or release depending on
amount of foot pressure applied to valve operating rod through the brake pedal linkage.
The control valve is a single poppet type valve with the atmospheric port and a vacuum port. The
vacuum port seal is a part of the valve body attached to the diaphragm assembly. The atmospheric
port is a part of the valve plunger which moves within the valve housing and vacuum power
diaphragm assembly.
These units require no maintenance and must be replaced as a complete assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 4829
Vacuum Brake Booster: Service and Repair
1. Remove master cylinder attaching nuts, slide master cylinder from mounting studs and support
on fender shield. Do not disconnect brake tubes
from master cylinder.
2. Disconnect vacuum hose from power brake unit. Do not remove check valve from booster. 3.
Install suitable screwdriver between center tang on retainer clip and brake pedal pin located under
instrument panel. Rotate screwdriver so retainer
clip center tang will pass over brake pedal pin.
4. Pull retainer clip from pin and discard clip. 5. Remove brackets from steel heater water line at
dash panel and left frame rail, if equipped. 6. On models equipped with manual transaxle, remove
clutch cable bracket at shock tower and position aside. 7. On all models, remove power brake unit
attaching nuts, then the power brake unit from vehicle. 8. Reverse procedure to install, ensuring to
use retainer new clip. Do not attempt to service booster, it can only be serviced by replacing
assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations
Electronic Brake Control Module: Locations
The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine
compartment. The CAB uses the wheel speed information from the wheel speed sensors to control
the ABS system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 4834
Electronic Brake Control Module: Description and Operation
The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine
compartment. The CAB uses the wheel speed information from the wheel speed sensors to control
the ABS system function. The CAB also monitors ABS operation and detects system faults.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 4835
Electronic Brake Control Module: Service and Repair
1. Turn ignition Off. 2. Remove speed control servo. 3. Disconnect wiring harness 60-way
connector from anti-lock brake controller. 4. Remove controller mounting bolts, then the controller.
5. Reverse procedure to install. 6. Torque controller attaching bolts to 40 in. lbs. and electrical
connector screw to 105 in. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
Engine Compartment Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4840
Engine Compartment & Transaxle Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4841
Brake Fluid Pressure Sensor/Switch: Description and Operation
The switch activates a light on the dash panel to indicate that one of the hydraulic systems has
failed. There are two basic types of switches. In some earlier models, as pressure falls in one
system, the normal pressure of the other system forces the piston to the inoperative side where it
contacts the switch terminal, causing the warning lights to illuminate.
On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one
side of the system, the piston in the valve is forced toward the failed side where it latches in
position and illuminates the warning light.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
I/P, Cowl & Steering Column Components
LH Kickpanel On Park Brake Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
The wheel speed sensors are located at each wheel and transmit wheel speed information to the
Controller Anti-Lock Brake.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Page 4848
Wheel Speed Sensor: Description and Operation
The wheel speed sensors are located at each wheel and transmit wheel speed information to the
Controller Anti-Lock Brake (CAB).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front
Wheel Speed Sensor: Service and Repair Front
Fig. 66 Front Speed Sensor Assembly
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove screw from clip
that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect
electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove
sensor head screw, then the sensor head from steering knuckle.
CAUTION: If sensor head is seized, use a punch and gently rock sensor back and forth until free.
Do not use pliers on sensor head.
5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and
Torque mounting bolt to 60 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front > Page 4851
Wheel Speed Sensor: Service and Repair Rear
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring
grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical
connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts,
then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head
from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and
forth until free. Do not use pliers on sensor head.
6. Reverse procedure to install. Torque sensor mounting bolt to 60 inch lbs. and U-bolt nuts to 65
ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Testing and Inspection
Clutch Switch: Testing and Inspection
Clutch (Inhibitor) Switch Test
1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end
of switch terminal.
2. Connect a test light to remaining terminal end and ground.
3. Test light should be on when pedal is in normal position and off when pedal is depressed.
4. If above step is not as specified, replace clutch switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Locations
Ignition Switch: Locations
I/P, Cowl & Steering Column Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Locations > Page 4860
Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Locations > Page 4861
Ignition Switch: Service and Repair
Fig. 10 Ignition switch replacement
1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES.
2. Remove left lower instrument panel cover.
3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle.
4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts.
5. Lower column and disconnect ignition switch electrical connector.
6. Position ignition lock cylinder in Lock position.
7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder
assembly.
8. Remove two ignition switch attaching screws, then the switch.
9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > 3 Speed A/T
Neutral Safety Switch: Locations 3 Speed A/T
Neutral/Park Safety Switch
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > 3 Speed A/T > Page 4866
Neutral Safety Switch: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > 3 Speed A/T > Page 4867
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions
Neutral Safety Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4870
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4871
Neutral Safety Switch: Electrical Diagrams
3 Speed A/T
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
4 Speed A/T
The Neutral Safety Switch wiring is part of the starting system circuit. See: Starting
System/Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Description and Operation > 3 Speed A/T
Neutral Safety Switch: Description and Operation 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
- It provides ground for the starter solenoid circuit through the selector lever in only Park and
Neutral positions.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Description and Operation > 3 Speed A/T > Page 4874
Neutral Safety Switch: Description and Operation 4 Speed A/T
The Neutral Safety Switch sends a signal to the EATX control module and the engine control
module, controlling starter relay operation when the transaxle is in any gear other than Park or
Neutral.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Testing and Inspection > 3 Speed A/T
Neutral Safety Switch: Testing and Inspection 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Testing and Inspection > 3 Speed A/T > Page 4877
Neutral Safety Switch: Testing and Inspection 4 Speed A/T
The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract
codes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Service and Repair > 3 Speed A/T
Neutral Safety Switch: Service and Repair 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Service and Repair > 3 Speed A/T > Page 4880
Neutral Safety Switch: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Service and Repair > 3 Speed A/T > Page 4881
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Engine Compartment & Front End Components.
On Left Fenderwell
Applicable to: 4-153/2.5L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 4886
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 4887
Engine Compartment & Transaxle Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical
Specifications
Battery: Electrical Specifications
Standard Battery
Standard Battery
BCI Group Number 34
Cranking Performance 500 A
Optional Battery
Optional Battery
BCI Group Number 34
Cranking Performance 625 A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical
Specifications > Page 4892
Battery: Mechanical Specifications
Optional Battery
Optional Battery
BCI Group Number 34
Cranking Performance 625 A
Standard Battery
Standard Battery
BCI Group Number 34
Cranking Performance 500 A
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Chrysler
Alternator: Specifications Chrysler, Rated Output
Chrysler, Rated Output
Identification Number- 5233508 Minimum Output 98 A at 1250 rpm
Note: At 15 Volts
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Chrysler > Page 4898
Alternator: Specifications Nippondenso, Rated Output
Nippondenso, Rated Output
Identification Number- 5227349 Minimum Output 87 A at 1250 rpm
Note: At 15 Volts
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Preliminary Check
Alternator: Testing and Inspection Preliminary Check
Prior to testing system, ensure battery is fully charged and all connections are good.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Preliminary Check > Page 4901
Alternator: Testing and Inspection Alternator Output Wire Resistance Test
On models equipped with airbags, before attempting to diagnose or service components,
disconnect and isolate battery ground cable, then wait at least 10 minutes prior to beginning
service. Failure to do so may result in accidental deployment or possible personal injury.
TESTING
1. Disconnect battery ground cable.
2. Disconnect "B+" lead at alternator output terminal.
Fig. 1 Alternator output wire resistance test. Except front wheel drive
3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and
disconnected "B+" lead wire.
4. Connect positive lead wire of a suitable voltmeter to disconnected "B+" lead wire, then connect
negative lead to battery positive post.
5. Remove air hose between Engine Controller and air cleaner.
6. On 1988-91 models except 1991 Front Wheel Drive vans and wagons and Jeep Cherokee,
Comanche and Wrangler, ground one end of a suitable jumper wire and probe green R3 wire. This
may generate a fault code. Use caution not to ground J2 wire. Both R3 and J2 wires are green on
alternator side of wire connector. On dash side of connector, R3 wire is green, while J2 wire is
blue.
Fig. 2 Alternator output wire resistance test. Front wheel drive
7. On 1991 Front Wheel Drive vans and wagons, connect suitable jumper wire to ground and K20
(green) terminal, at rear of alternator. This may generate a fault code. Do not connect A21 (blue)
circuit to ground, as fusible link will burn.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Preliminary Check > Page 4902
Fig. 3 Alternator output wire resistance test
8. On 1991-92 Jeep Cherokee, Comanche and Wrangler, connect suitable jumper wire to ground
and K20 (green) lead wire at rear of alternator. This will generate a fault code. Do not connect
A142 (green/orange) lead wire to ground.
9. On all 1992 models except Jeep Cherokee, Comanche and Wrangler, connect suitable jumper
wire to ground and K20 (green) lead wire at rear of alternator. This will generate a fault code. Do
not connect A142 (blue) lead wire to ground.
10. On all models, connect a suitable engine tachometer, then reconnect battery ground cable.
11. Ensure carbon pile is in OPEN or OFF position, then connect a variable carbon pile rheostat to
battery terminals.
12. Start engine and operate at idle speed, then adjust carbon pile and engine speed to maintain a
20 amp circuit flow. Note voltmeter reading. Voltmeter reading should not exceed .5 volt.
TESTING RESULTS
1. If a higher than specified voltage drop is indicated, clean and tighten all connectors in charging
circuit. A voltage drop test may be performed at each connector to locate point of excessive
resistance.
2. If charging circuit resistance test was satisfactory, disconnect battery ground cable, then the
ammeter, voltmeter, carbon pile and tachometer.
3. Remove jumper wire.
4. Connect battery ground cable, then the hose between Engine Controller and air cleaner.
5. On models quipped with on board diagnostics, erase codes using DRBII test tool or equivalent.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Preliminary Check > Page 4903
Alternator: Testing and Inspection Current Output Test
On models equipped with airbags, before attempting to diagnose or service components,
disconnect and isolate battery ground cable, then wait at least 10 minutes prior to beginning
service. Failure to do so may result in accidental deployment or possible personal injury.
TESTING
1. Disconnect battery ground cable.
2. Disconnect "B+" lead at alternator output terminal.
Fig. 4 Alternator current output test. Except front wheel drive
3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and
disconnected "B+" lead wire.
4. Connect positive lead of a suitable voltmeter to "B+" terminal of alternator, then connect negative
lead to suitable ground.
5. Connect a suitable engine tachometer, then reconnect battery ground cable.
6. Connect a variable carbon pile rheostat between battery terminals, ensuring carbon piles are in
Open or Off position.
7. Remove air hose between Engine Controller and air cleaner.
8. On 1988-91 models except 1991 Front Wheel Drive vans and wagons and Jeep Cherokee,
Comanche and Wrangler, ground one end of a suitable jumper wire and probe green R3 wire. This
may generate a fault code. Use caution not to ground J2 wire. Both R3 and J2 wires are green on
alternator side of wire connector. On dash side of connector, R3 wire is green, while J2 wire is
blue.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Preliminary Check > Page 4904
Fig. 5 Alternator current output test. Front wheel drive
9.
On 1991 Front Wheel Drive vans and wagons, connect suitable jumper wire to ground and K20
(green) terminal, at rear of alternator. This may generate a fault code. Do not connect A21 (blue)
circuit to ground, as fusible link will burn.
Fig. 6 Alternator current output test
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Preliminary Check > Page 4905
10. On 1991-92 Jeep Cherokee, Comanche and Wrangler, connect suitable jumper wire to ground
and K20 (green) lead wire at rear of alternator. This will generate a fault code. Do not connect
A142 (green/orange) lead wire to ground.
Fig. 3 Alternator output wire resistance test
11. On all 1992 models except Jeep Cherokee, Comanche and Wrangler, connect suitable jumper
wire to ground and K20 (green) lead wire at rear of alternator. This will generate a fault code. Do
not connect A142 (blue) lead wire to ground.
12. On all models, start engine and operate at idle speed, then adjust carbon pile and engine
speed in increments until a speed of 1250 RPM at 15 volts is obtained. Do not allow voltmeter
range to exceed 16 volts during testing.
TEST RESULTS
1. Note ammeter reading. Ammeter reading should be within specified limits noted in specification
charts in individual truck chapters.
2. If reading is less than specified and alternator wire resistance is not excessive, alternator is
defective.
3. After completion of current output test, turn off carbon pile and ignition switch, then disconnect
battery ground cable.
4. Remove ammeter, voltmeter, tachometer and carbon pile, then reconnect "B+" lead to alternator
output terminal.
5. Disconnect jumper wire, then connect air hose from Engine Controller to air cleaner.
6. Connect battery ground cable.
7. On models quipped with on board diagnostics, erase codes using DRBII test tool or equivalent.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Page 4906
Alternator: Service and Repair
1. Disconnect battery ground cable.
2. Remove alternator drive belt, then the alternator mounting bolts.
3. Separate alternator from mounting bracket and remove electrical connectors.
4. Remove alternator from vehicle.
5. Reverse procedure to install. Torque mounting bolts to 250 inch lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Testing and Inspection
Voltage Regulator: Testing and Inspection
Voltage regulator is internal to the PCM. For testing see Charging System/Testing and Inspection
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing
and Inspection
Clutch Switch: Testing and Inspection
Clutch (Inhibitor) Switch Test
1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end
of switch terminal.
2. Connect a test light to remaining terminal end and ground.
3. Test light should be on when pedal is in normal position and off when pedal is depressed.
4. If above step is not as specified, replace clutch switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Standard Column
Ignition Lock: Service and Repair Standard Column
1. If equipped, disarm airbag system as described under MAINTENANCE PROCEDURES.
2. Remove steering wheel.
Steering column cover, silencer & reinforcement removal
3. Remove steering column cover and silencer.
4. Remove shift indicator operating cable from slot in shift housing.
5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors.
6. Remove screws attaching turn signal lever cover to lock housing, then lever cover.
7. Remove washer/wiper switch assembly.
8. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching
screws.
9. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch.
10. Remove turn signal/hazard switch attaching screws.
Turn signal switch replacement
11. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up
from column while straightening and guiding wires up through column opening.
12. Remove key lamp assembly retaining screw, then key lamp assembly.
13. Remove retaining screws holding bearing housing to lock housing.
14. Remove snap ring from upper end of steering shaft, then bearing housing from shaft.
15. Remove lock plate spring and lock plate from steering shaft.
16. Remove ignition key.
17. Remove buzzer/chime switch attaching screws, then remove switch.
18. Remove two screws attaching ignition switch to steering column, then remove switch by
rotating it 90° and sliding from rod.
19. Remove two screws attaching dimmer switch, then disengage dimmer switch from actuator rod.
20. Remove two bell crank attaching screws, then slide bell crank up into lock housing until it can
be disconnected from ignition switch actuator rod.
Fig. 7 Ignition lock removal. W/standard column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Standard Column > Page 4918
21. With lock cylinder in Lock position, insert a small diameter screwdriver into lock cylinder release
holes and push inward until spring loaded lock cylinder retainers release.
22. Remove lock cylinder from lock housing bore.
23. Reverse procedure to install. Rearm airbag system. Lock cylinder and ignition switch must be in
Lock position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Standard Column > Page 4919
Ignition Lock: Service and Repair Tilt Column
Tilt Column
1. If equipped, disarm airbag system as described under MAINTENANCE PROCEDURES.
2. Remove steering wheel.
Steering column cover, silencer & reinforcement removal
3. Remove steering column cover and silencer.
4. Remove shift indicator operating cable from slot in shift housing.
5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors.
a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove
ignition key lamp assembly, then remove knob off washer/wiper switch assembly. c. Pull hider up
control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate
control lever shaft to full clockwise position, then remove shaft from washer/wiper switch.
Lock plate removal. Models w/tilt column
e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring
out of groove with a suitable screwdriver.
The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will
turn too easily and make removal difficult.
f. Remove lock plate, cancelling cam and upper bearing spring.
g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard
switch attaching screws, Place shift bowl in Low position.
Turn signal switch replacement
6. Remove turn signal/hazard warning switch assembly by gently pulling switch up from column
while straightening and guiding wires up through column opening.
7. Remove ignition key lamp.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Standard Column > Page 4920
Fig. 2 Ignition lock removal. Models w/tilt column
8. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock
cylinder release holes and push inward until spring loaded lock cylinder retainers release.
9. Reverse procedure to install. Rearm airbag system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information >
Locations
Ignition Switch: Locations
I/P, Cowl & Steering Column Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information >
Locations > Page 4924
Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information >
Locations > Page 4925
Ignition Switch: Service and Repair
Fig. 10 Ignition switch replacement
1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES.
2. Remove left lower instrument panel cover.
3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle.
4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts.
5. Lower column and disconnect ignition switch electrical connector.
6. Position ignition lock cylinder in Lock position.
7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder
assembly.
8. Remove two ignition switch attaching screws, then the switch.
9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > 3 Speed A/T
Neutral Safety Switch: Locations 3 Speed A/T
Neutral/Park Safety Switch
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > 3 Speed A/T > Page 4930
Neutral Safety Switch: Locations 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > 3 Speed A/T > Page 4931
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Diagram Information and Instructions
Neutral Safety Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 4934
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 4935
Neutral Safety Switch: Electrical Diagrams
3 Speed A/T
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
4 Speed A/T
The Neutral Safety Switch wiring is part of the starting system circuit. See: Diagrams/Electrical
Diagrams
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Description and Operation > 3 Speed A/T
Neutral Safety Switch: Description and Operation 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
- It provides ground for the starter solenoid circuit through the selector lever in only Park and
Neutral positions.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Description and Operation > 3 Speed A/T > Page 4938
Neutral Safety Switch: Description and Operation 4 Speed A/T
The Neutral Safety Switch sends a signal to the EATX control module and the engine control
module, controlling starter relay operation when the transaxle is in any gear other than Park or
Neutral.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Testing and Inspection > 3 Speed A/T
Neutral Safety Switch: Testing and Inspection 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Testing and Inspection > 3 Speed A/T > Page 4941
Neutral Safety Switch: Testing and Inspection 4 Speed A/T
The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract
codes.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Service and Repair > 3 Speed A/T
Neutral Safety Switch: Service and Repair 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Service and Repair > 3 Speed A/T > Page 4944
Neutral Safety Switch: Service and Repair 4 Speed A/T
Sound Cover Installed
PRNDL Switch
This applies to the 4 speed electronic automatic transaxle.
The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5
Neutral Safety Switch
The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Service and Repair > 3 Speed A/T > Page 4945
Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so
may result in leakage of transmission fluid.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Starter Replacement - Information Only
Starter Motor: Technical Service Bulletins Starter Replacement - Information Only
NO.: 08-12-93
GROUP: Electrical
DATE: Mar. 19, 1993
SUBJECT: 3.0L Engine Starter Replacement
MODELS:
1989 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
If the starter motor on subject vehicles requires replacement, use only P/N 4557284.
It may be necessary to adjust the wiring harness at the points where it is secured to the body in
order to obtain an appropriate wiring length for connection to the replacement starter motor.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications
Starter Motor: Electrical Specifications
Starter Motor Specifications
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications > Page 4952
Starter Motor: Mechanical Specifications
Starter Motor Specifications
Starter To Transaxle Bellhousing Bolt 40 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 4953
Starter Motor: Locations
View Of Engine & Transmission Components.
Front Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 4954
Starter Motor: Description and Operation
Two types of starters are used. The first type is a direct drive starter motor with an overrunning
clutch type starter drive. A solenoid switch is mounted on the starter motor. The second type is a
permanent magnet reduction gear starter. A planetary gear train transmits power between starter
motor and pinion shaft. The structure is different on both type starters, but electrical wiring is the
same.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 4955
Fig. 1 Starter motor diagnosis
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 4956
Starter Motor: Service and Repair
1. Disconnect battery ground cable.
2. On 3.0L/V6-181 models, loosen air pump tube at exhaust manifold, then swivel tube away from
starter.
3. On all models, disconnect all electrical connectors from starter motor.
4. Remove starter motor attaching bolts.
5. Remove starter.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
Engine Compartment & Front End Components.
On Left Fenderwell
Applicable to: 4-153/2.5L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 4960
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 4961
Engine Compartment & Transaxle Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Testing and Inspection
Starter Solenoid: Testing and Inspection
Bench Testing Starter Solenoid
Fig. 4 Bosch starter solenoid terminal identification
Fig. 5 Nippondenso starter solenoid terminal identification
1. Remove starter assembly from vehicle.
2. Disconnect field coil wire from field coil terminal.
3. Check for continuity between solenoid terminal and field coil terminal. Continuity should exist.
4. Check for continuity between solenoid terminal and solenoid housing. Continuity should exist.
5. If there is no continuity in either step 3 or 4, solenoid has an open circuit and must be replaced.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Locations
Circuit Breaker: Locations
Circuit Location Amp
Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats &
Mirror.........Fuse Block...........30
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions
Circuit Breaker: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 4971
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 4972
Circuit Breaker: Electrical Diagrams
Circuit Location Amp
Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats &
Mirror.........Fuse Block...........30
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Page 4973
Circuit Breaker: Testing and Inspection
NOTE: Perform SWITCH VOLTAGE TEST, and verify that the battery is fully charged before
starting this test.
1. Locate the circuit breaker (in the fuse box) and connect the positive lead of a voltmeter to the
light green terminal. Connect the other lead of the voltmeter to a good ground and check that there
is battery voltage.
2. If battery voltage is not present, connect the voltmeter to the other (battery) side of the circuit
breaker and check for battery voltage.
3. If battery voltage is present, the circuit breaker is defective and needs to be replaced. If battery
voltage is not present, check for an open wire in the harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Locations
Fuse Block: Locations
Lower I/P Components
RH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4979
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4980
Fuse Block: Connector Views
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4981
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4982
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4983
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4984
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4985
Fuse Block: Electrical Diagrams
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4986
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4987
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4988
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4989
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4990
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > A604 EATX - Wiring Repair Package
Multiple Junction Connector: Technical Service Bulletins A604 EATX - Wiring Repair Package
NO.: 08-16-90
GROUP: ELECTRICAL
DATE: Sept. 24, 1990
SUBJECT: A604 EATX Wiring Harness/ Electronic Connector Repair Package
MODEL YEARS/BODY CODES:
1989-90 AC - DYNASTY/NEW YORKER/NEW YORKER LANDAU AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
1990 AA - ACCLAIM/SPIRIT AG - DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE
AY - IMPERIAL/FIFTH AVENUE
DISCUSSION
When inspecting wiring and connectors, look for cut wiring or worn through insulation, terminal
push-out, and spreading of terminals. These problems have led to intermittent setting of fault codes
12, 39, and 41 among others. Wiring must be properly routed and secure to avoid sharp or moving
parts. Connector seals, covers, and shields must be present and in good shape. Terminals must be
clean and fully engaged with a tight fit. The 60-way, 8-way and other sealer connectors for the
A604 EATX should contain Mopar Lubriplate grease PN 4549615 in the female terminals.
When wiring, connectors or terminals need repair on an A604 EATX the following service parts are
now available.
REQUIRED PARTS FOR REPAIRS
Repair Package - 8-Way Solenoid Connector 4419476
(Connector Assembly on Wire w/Heat Shrink) Repair Package - 2-Way Connector (For
4419478
Output and Turbine Speed Sensors) Repair Package - 60-Way Connector
4419479
(14 Two Terminal Leads) Repair Package - 60-Way Insulator
4419491
60-Way Connector Outer Shield 4400980
REQUIRED PARTS FOR MAKING A GAUGE
0.045 in. Male Pin Terminal - 2-Way 4400110
0.090 in. Male Pin Terminal - 8-Way 4368163
Heat Shrink Tubing - 0.25 in. Diameter 4419644
PROCEDURE FOR MAKING A GAUGE
To properly check a terminal for spreading, a gauge is required. To make a gauge, select the
correct male pins from the parts list above (pins for gauging the 60-way connector are included in
Repair Package PN 4419479). Two pins are required to make each gauge. Insert the base of a pin
into each end of a single piece of heat shrink tubing PN 4419644. Heat evenly until the tubing
shrinks tightly onto the base of both pins. The shrink tubing will now serve as a handle while
gauging terminals.
INSPECTING CONNECTORS
Inspect connectors for pushed out terminals by removing from the A604 EATX and looking at the
face of the connectors. If terminals are pushed out, carefully remove the locking wedge and push in
the terminals until they snap into position. Carefully install the wedge until it is flush with the outer
surface. Make sure that all of the terminals remain fully seated. If the wedge does not go in all of
the way, clear the wedge cavity and reinstall the wedge.
To inspect the connector for spread terminals, take the appropriate size gauge and insert it into
each of the female connector pins. The terminals should mate snugly with the gauge.
Verify proper transaxle operation after service.
NOTE: WHEN REPLACING EITHER THE SPEED SENSOR OR SOLENOID PACK, MAKE SURE
THAT ALL TERMINALS HAVE AN INTERFERENCE FIT.
60-WAY CONNECTOR REPAIRS
If the 60-way insulator is damaged or the locking fingers are broken, replace the insulator using
repair package PN 4419491. If terminals are damaged or
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > A604 EATX - Wiring Repair Package > Page 4995
spread, replace them using Repair Package 4419479 and the following procedure.
1. Remove the shield, wedge, and tape as needed. Remove the bad terminal while flexing the
plastic locking finger.
2. Cut the wire with the bad terminal from the wiring harness. Strip one half inch of insulation from
the remaining wire and slide on a piece of heat shrink tubing included in the Repair Package.
3. Select from the Repair Package a wire of the same base color as the wire just cut from the
harness. Cut the wire to the proper length and remove one half inch of insulation from the wire and
twist the two bare ends around each other.
4. Solder the joint together using a ROSIN CORE SOLDER. Center the heat shrink tubing over the
joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes
out of both ends of heat shrink tubing.
5. Insert the new terminal and fully seat. Install the wedge, retape the harness and snap on the
shield. If the shield is damaged, replace with PN 4400980.
6. Connect the 60-way connector and torque to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
8-WAY CONNECTOR
If the 8-way insulator is damaged, the locking fingers are broken or terminals are spread replace
the connector using Repair Package PN 4419476 and the following procedure.
1. With the vehicle raised disconnect the wiring from the solenoid pack and transmission switches
and drop the wiring for access.
2. Remove the wire covering, cut the leads to the damaged 8-way at staggered even lengths and
place a piece of heat shrink tubing on each wire.
3. Cut the matching wires on the new 8-way to staggered even lengths (allowing extra lengths for
solder connections) so that the length of the new wiring is the same as the original wiring.
4. Strip one half inch of insulation from each wire and twist each pair of matching wires together.
Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and
heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of heat shrink tubing.
5. Install the covering and connect the wiring to the solenoid and switches following the original
routing.
6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
2-WAY CONNECTOR REPAIRS
If the 2-way insulator is damaged, the locking fingers are broken or terminals are spread replace
the connector using Repair Package PN 4419478 and the following procedure.
1. With the vehicle raised, disconnect the wiring from the solenoid pack and transmission switches
and drop the wiring for access.
2. Cut the leads to the damaged 2-way at staggered even lengths and place a piece of heat shrink
tubing on each wire.
3. Cut the matching wires on the new 2-way to staggered even lengths (allowing extra length for
solder connections) so that the length of the new wiring is the same as the original wiring.
4. Strip one half inch of insulation from each wire and twist each pair of matching wires together.
Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and
heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tube.
5. Install the wiring in its original routing.
6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Page 4996
Multiple Junction Connector: Locations
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations
Circuit Breaker: Locations
Circuit Location Amp
Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats &
Mirror.........Fuse Block...........30
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions
Circuit Breaker: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5003
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5004
Circuit Breaker: Electrical Diagrams
Circuit Location Amp
Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats &
Mirror.........Fuse Block...........30
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page
5005
Circuit Breaker: Testing and Inspection
NOTE: Perform SWITCH VOLTAGE TEST, and verify that the battery is fully charged before
starting this test.
1. Locate the circuit breaker (in the fuse box) and connect the positive lead of a voltmeter to the
light green terminal. Connect the other lead of the voltmeter to a good ground and check that there
is battery voltage.
2. If battery voltage is not present, connect the voltmeter to the other (battery) side of the circuit
breaker and check for battery voltage.
3. If battery voltage is present, the circuit breaker is defective and needs to be replaced. If battery
voltage is not present, check for an open wire in the harness.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations
Fuse Block: Locations
Lower I/P Components
RH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5011
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5012
Fuse Block: Connector Views
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5013
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5014
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5015
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5016
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5017
Fuse Block: Electrical Diagrams
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5018
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5019
Fuse Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5020
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5021
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5022
Fuse Application Chart Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > A604 EATX - Wiring Repair Package
Multiple Junction Connector: Technical Service Bulletins A604 EATX - Wiring Repair Package
NO.: 08-16-90
GROUP: ELECTRICAL
DATE: Sept. 24, 1990
SUBJECT: A604 EATX Wiring Harness/ Electronic Connector Repair Package
MODEL YEARS/BODY CODES:
1989-90 AC - DYNASTY/NEW YORKER/NEW YORKER LANDAU AS - CARAVAN/GRAND
CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
1990 AA - ACCLAIM/SPIRIT AG - DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE
AY - IMPERIAL/FIFTH AVENUE
DISCUSSION
When inspecting wiring and connectors, look for cut wiring or worn through insulation, terminal
push-out, and spreading of terminals. These problems have led to intermittent setting of fault codes
12, 39, and 41 among others. Wiring must be properly routed and secure to avoid sharp or moving
parts. Connector seals, covers, and shields must be present and in good shape. Terminals must be
clean and fully engaged with a tight fit. The 60-way, 8-way and other sealer connectors for the
A604 EATX should contain Mopar Lubriplate grease PN 4549615 in the female terminals.
When wiring, connectors or terminals need repair on an A604 EATX the following service parts are
now available.
REQUIRED PARTS FOR REPAIRS
Repair Package - 8-Way Solenoid Connector 4419476
(Connector Assembly on Wire w/Heat Shrink) Repair Package - 2-Way Connector (For
4419478
Output and Turbine Speed Sensors) Repair Package - 60-Way Connector
4419479
(14 Two Terminal Leads) Repair Package - 60-Way Insulator
4419491
60-Way Connector Outer Shield 4400980
REQUIRED PARTS FOR MAKING A GAUGE
0.045 in. Male Pin Terminal - 2-Way 4400110
0.090 in. Male Pin Terminal - 8-Way 4368163
Heat Shrink Tubing - 0.25 in. Diameter 4419644
PROCEDURE FOR MAKING A GAUGE
To properly check a terminal for spreading, a gauge is required. To make a gauge, select the
correct male pins from the parts list above (pins for gauging the 60-way connector are included in
Repair Package PN 4419479). Two pins are required to make each gauge. Insert the base of a pin
into each end of a single piece of heat shrink tubing PN 4419644. Heat evenly until the tubing
shrinks tightly onto the base of both pins. The shrink tubing will now serve as a handle while
gauging terminals.
INSPECTING CONNECTORS
Inspect connectors for pushed out terminals by removing from the A604 EATX and looking at the
face of the connectors. If terminals are pushed out, carefully remove the locking wedge and push in
the terminals until they snap into position. Carefully install the wedge until it is flush with the outer
surface. Make sure that all of the terminals remain fully seated. If the wedge does not go in all of
the way, clear the wedge cavity and reinstall the wedge.
To inspect the connector for spread terminals, take the appropriate size gauge and insert it into
each of the female connector pins. The terminals should mate snugly with the gauge.
Verify proper transaxle operation after service.
NOTE: WHEN REPLACING EITHER THE SPEED SENSOR OR SOLENOID PACK, MAKE SURE
THAT ALL TERMINALS HAVE AN INTERFERENCE FIT.
60-WAY CONNECTOR REPAIRS
If the 60-way insulator is damaged or the locking fingers are broken, replace the insulator using
repair package PN 4419491. If terminals are damaged or
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > A604 EATX - Wiring Repair Package > Page 5027
spread, replace them using Repair Package 4419479 and the following procedure.
1. Remove the shield, wedge, and tape as needed. Remove the bad terminal while flexing the
plastic locking finger.
2. Cut the wire with the bad terminal from the wiring harness. Strip one half inch of insulation from
the remaining wire and slide on a piece of heat shrink tubing included in the Repair Package.
3. Select from the Repair Package a wire of the same base color as the wire just cut from the
harness. Cut the wire to the proper length and remove one half inch of insulation from the wire and
twist the two bare ends around each other.
4. Solder the joint together using a ROSIN CORE SOLDER. Center the heat shrink tubing over the
joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes
out of both ends of heat shrink tubing.
5. Insert the new terminal and fully seat. Install the wedge, retape the harness and snap on the
shield. If the shield is damaged, replace with PN 4400980.
6. Connect the 60-way connector and torque to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
8-WAY CONNECTOR
If the 8-way insulator is damaged, the locking fingers are broken or terminals are spread replace
the connector using Repair Package PN 4419476 and the following procedure.
1. With the vehicle raised disconnect the wiring from the solenoid pack and transmission switches
and drop the wiring for access.
2. Remove the wire covering, cut the leads to the damaged 8-way at staggered even lengths and
place a piece of heat shrink tubing on each wire.
3. Cut the matching wires on the new 8-way to staggered even lengths (allowing extra lengths for
solder connections) so that the length of the new wiring is the same as the original wiring.
4. Strip one half inch of insulation from each wire and twist each pair of matching wires together.
Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and
heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of heat shrink tubing.
5. Install the covering and connect the wiring to the solenoid and switches following the original
routing.
6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
2-WAY CONNECTOR REPAIRS
If the 2-way insulator is damaged, the locking fingers are broken or terminals are spread replace
the connector using Repair Package PN 4419478 and the following procedure.
1. With the vehicle raised, disconnect the wiring from the solenoid pack and transmission switches
and drop the wiring for access.
2. Cut the leads to the damaged 2-way at staggered even lengths and place a piece of heat shrink
tubing on each wire.
3. Cut the matching wires on the new 2-way to staggered even lengths (allowing extra length for
solder connections) so that the length of the new wiring is the same as the original wiring.
4. Strip one half inch of insulation from each wire and twist each pair of matching wires together.
Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and
heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tube.
5. Install the wiring in its original routing.
6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Page 5028
Multiple Junction Connector: Locations
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear
Alignment: Customer Interest Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5038
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5039
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear
Alignment: All Technical Service Bulletins Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5045
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5046
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5047
Alignment: By Symptom
Technical Service Bulletin # 020790 Date: 901105
Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5048
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5049
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Technical Service Bulletin # 020790 Date: 901105
Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5050
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Fig. 3-Shim Installation for Positive Camber
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5051
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten
adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5052
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Technical Service Bulletin # 020790 Date: 901105
Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5053
Fig. 2-Shim Installation for Toe-in
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5054
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten
adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Technical Service Bulletin # 020790 Date: 901105
Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5055
reverse sign convention; a total toein on direct reading charts is actually toe-out while driving.
Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Fig. 3-Shim Installation for Positive Camber
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5056
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten
adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 5057
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front
Alignment Specifications
Front Wheel Alignment Specifications
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front
Alignment Specifications > Page 5060
Rear Wheel Alignment Specifications
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front
Alignment
Alignment: Service and Repair Front Alignment
Camber
Fig. 1 Camber adjustment
To adjust camber, loosen cam and through bolts. Rotate upper cam bolt to move top of wheel in or
out to achieve specified camber angle. Torque cam bolt nut to 75 ft. lbs. plus an additional 1/4 turn.
Caster
The caster angle on these vehicles cannot be adjusted.
Preliminary Inspection
Prior to wheel alignment, ensure tires are at recommended pressure, are of equal size and have
approximately the same wear pattern. Check front wheel and tire assembly for radial runout and
inspect lower ball joints and steering linkage for looseness. Check front and rear springs for
sagging or damage. Front suspension inspections should be performed on a level floor or
alignment rack with fuel tank at capacity and vehicle free of luggage and passenger compartment
load.
Before each alignment reading, the vehicle should be bounced an equal number of times from the
center of the bumper alternating first from the rear, then the front, and releasing at bottom of down
cycle.
Toe Adjustment
Fig. 2 Toe-in adjustment
To adjust toe-in, center steering wheel and hold in position with a suitable tool. Loosen tie rod
locknuts and rotate rod, to adjust toe-in to specifications. Use care not to twist steering gear rubber
boots. Torque tie rod locknuts to 55 ft. lbs. Adjust position of steering gear rubber boots. Remove
steering wheel holding tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front
Alignment > Page 5063
Alignment: Service and Repair Rear Alignment
Rear wheel alignment is not adjustable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Fig. 9 Steering knuckle assembly
Fig. 10 Steering knuckle assembly
REMOVAL
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and driveshaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut.
Ensure splined driveshaft is free to separate from spline in hub during knuckle removal. A pulling
force on shaft can separate
inner C/V joint. Tap lightly with brass drift, if required.
5. Disconnect tie rod end from steering arm with a suitable puller. 6. Disconnect brake hose
retainer from strut damper. 7. Remove clamp bolt securing ball joint stud into steering knuckle, then
the brake caliper adapter screw and washer assemblies. 8. Support caliper with a piece of wire. Do
not hang by brake hose. 9. Remove rotor, then separate ball joint stud from knuckle assembly.
10. Remove knuckle assembly from vehicle. Support driveshaft during knuckle removal. Do not
permit driveshaft to hang after separating
steering knuckle from vehicle.
INSTALLATION
1. Place steering knuckle on lower ball joint stud and the driveshaft through hub. 2. Install and
tighten ball joint to steering knuckle clamp bolt to specifications. 3. Install tie rod end into steering
arm and tighten nut to specifications. Install cotter pin. 4. Install rotor. 5. Install caliper over rotor
and position adapter to steering knuckle. Install adapter to knuckle attaching bolts and tighten to
specifications. 6. Attach brake hose retainer to strut damper and tighten attaching screw to
specifications. 7. Install hub nut assembly as follows:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 5068
a. With brakes applied, install hub nut and tighten to specifications. b. Install spring washer, locknut
and new cotter pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
1. With fluid at room temperature, ensure reservoir is at correct level. 2. Allow fluid to settle for a
minimum of two minutes. 3. Start and run engine for a few minutes. 4. Add fluid as necessary, then
repeat above steps until fluid level is constant. 5. Raise front wheels off ground. 6. Start engine,
then slowly turn steering wheel left and right. Lightly contacting stops. 7. Stop engine and check
fluid level, fill as necessary. 8. If fluid is extremely foamy, let stand for a few minutes, then repeat
procedure.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications
Power Steering Pressure Specifications
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 5076
Power Steering Pump: Service and Repair
1. Disconnect vapor separator hose and wires from air conditioning clutch cycling switch. 2.
Remove drive belt adjustment locking screw, then pump end hose bracket nut. 3. Raise and
support vehicle. 4. Disconnect return hose from gear tube, then drain oil from pump. 5. Remove
right side splash shield. 6. Disconnect both hoses from pump. Cap all open hose ends and ports. 7.
Remove lower stud nut and pivot screw from pump. 8. Lower vehicle and remove belt from pulley.
9. Move pump rearward to clear mounting bracket and remove adjustment bracket.
10. Rotate pump clockwise so pump pulley faces rear of vehicle, remove pump from vehicle. 11.
Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag System Arming and Disarming
1. Place ignition switch in lock position.
2. Disconnect and tape battery ground cable connector.
3. Wait at least 1 minute after disconnecting battery ground cable before performing any further
repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a
short time even after battery has been disconnected.
4. After repairs are performed, connect battery ground cable.
5. From passenger side of vehicle, turn ignition switch to On position.
6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to
indicate if SRS system is functioning correctly.
7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Application
and ID
Steering Gear: Application and ID
88-92 Ram Van, Varavan & Voyager TRW Rack & Pinion
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Application
and ID > Page 5084
Steering Gear: Description and Operation
Fig. 1 Rack & pinion steering gear
The steering gear assembly used on Chrysler Corp. front wheel drive trucks and vans and Dodge
Dakota, consists of a housing which contains a toothed rack, a pinion, rack slipper and rack slipper
spring. The steering gear rack and pinion assembly converts rotational movement of the pinion
assembly into transverse movement of the rack. Tie rods and tie rod ends transmit this movement
to the steering arms and wheels while accommodating suspension movement at the same time.
The tie rods are coupled to the ends of the rack. This connection is protected by a bellows type oil
seal which retains steering gear lubricant. The pinion runs on straddle mounted ball bearings. The
lower bearing is incorporated in the pinion housing. The upper bearing is swagged to the pinion
shaft. Lock to lock stops are built into the steering gear. The 1991-92 Dakota rack and pinion gears
have a larger diameter stud than previous years, so these are not interchangeable.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Hard Steering
Steering Gear: Testing and Inspection Hard Steering
1. Tires improperly inflated. 2. Low fluid level. 3. Loose belt. 4. Lack of ball joint lubrication. 5. Low
pump pressure. 6. High internal gear leak.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Hard Steering > Page 5087
Steering Gear: Testing and Inspection Poor Return to Center
1. Tires improperly inflated. 2. Improper front wheel alignment. 3. Lack of lubrication in ball joint. 4.
Steering column U-joints misaligned. 5. Improperly positioned dash cover. 6. Steering wheel
rubbing. 7. Tight steering shaft bearings. 8. Excessive friction coupling universal joint. 9. High
friction in steering gear.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Hard Steering > Page 5088
Steering Gear: Testing and Inspection Steering Wheel Binds
1. Low fluid level. 2. Tires improperly inflated. 3. Lack of lube in ball joints or outer tie rod ends. 4.
Loose pump belt. 5. Faulty pump flow. 6. Excessive friction in steering column or intermediate
shaft. 7. Steering column coupling binding. 8. Excessive friction in gear.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Hard Steering > Page 5089
Steering Gear: Testing and Inspection Steering Wheel Shudder
1. Air in power steering system. 2. Tires improperly inflated. 3. Excessive engine vibration. 4. Faulty
accessory drive belt tensioner. 5. Overcharged air conditioning system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Page 5090
Steering Gear: Adjustments
1. With rack placed in center position, attach rack support cover to gear housing, then tighten cover
to specifications using torque wrench socket
MB990607-A or equivalent. Back off cover approximately 10°, then install and tighten locking nut to
specifications.
2. Rotate pinion gear at a rate of one revolution every 4 to 6 seconds using preload socket
CT-1108 and a suitable torque wrench. Total pinion
preload should be 5-11 lb-in. NOTE: Measure starting torque through whole stroke of rack.
3. If measured values are not within specifications, readjust rack support cover, then recheck. 4. If
still not within specifications, check rack support cover, rack support spring and rack support and
replace parts as necessary.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear Replacement
Steering Gear: Service and Repair Steering Gear Replacement
FWD MODELS
1. Raise and support vehicle, then remove front wheels. 2. Remove tie rod ends using a suitable
puller. 3. On all models, remove splash shields and boot seal shields, then the fluid lines to pump
on power steering gear only. 4. Disconnect tie rod ends from steering knuckles. 5. Remove
crossmember to steering gear attaching bolts, then the steering gear from left side of vehicle. 6.
Reverse procedure to install noting the following:
a. For manual gear, make sure master serrations are in line. b. The right rear crossmember bolt is
a pilot bolt that correctly locates the crossmember. Tighten this bolt first. Tighten all four
crossmember
bolts to specifications. Proper torque is very important.
c. Tighten four bolts attaching steering gear to crossmember to specifications.
AWD MODELS
Fig. 19 Bridge assembly. AWD models
Fig. 20 Steering gear assembly. AWD models
1. Remove steering column as described in STEERING WHEEL. 2. Remove tie rod ends from
steering knuckle using suitable puller. 3. Remove two bolts and two nuts attaching bridge assembly
to crossmember. Gain access to bolts through holes in top of bridge assembly. 4. Remove
crossmember to frame rail attaching bolts. Using a suitable jack, lower and suspend crossmember
from lower control arm. Do not remove
crossmember from vehicle.
5. Disconnect power steering pump, pressure and return lines from steering gear. 6. Remove
power steering hose to crossmember bracket. 7. Remove four bolts attaching steering gear to
crossover bridge. Note length during removal. 8. Remove lower steering column coupling from
steering gear. Drive roll pin from coupler using suitable drift.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear Replacement > Page 5093
9. Remove steering gear from vehicle by pulling out from driver's side wheelwell.
10. Reverse procedure to install. Tighten to specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear Replacement > Page 5094
Steering Gear: Service and Repair Rack and Pinion
Disassembly
On 1989-92 models, gear is not repairable. If a problem is indicated, unit must be replaced.
1. Disarm airbag system, refer to Air Bags and Seat Belts/Air Bags (Supplemental Restraint
Systems)/Service and Repair. 2. Mark location of tie rod end on tie rod, loosen jam nut and remove
tie rod end.
Fig. 1 Exploded view of TRW power rack & pinion steering gear
3. Remove jam nuts and bellow clamps. 4. Mark breather tube location on bellows and remove
from steering gear.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear Replacement > Page 5095
Fig. 2 Removing inner tie rod from rack
5. using a wrench to prevent rack from rotating, position a wrench on inner tie rod pivot housing
flats. Turn housing counterclockwise until tie rod
assembly separates from rack.
Fig. 3 Exploded view of rack bearing
6. Loosen adjuster plug locknut then, remove adjuster plug, spring and rack bearing.
Fig. 4 Removing rack bulkhead retaining wire
7. Using a punch, rotate the right side rack bulkhead retaining wire clockwise to expose end of
retaining wire. Pull retaining wire out of cylinder slot. 8. Turn stub shaft, moving rack to the right
forcing the bulkhead out of the housing. Use drain pan to catch excess fluid. Remove rack. 9.
Remove input shaft retaining ring, followed by pinion plug.
Fig. 5 Removing pinion locknut from pinion shaft
10. While holding stub shaft in place with holding fixture No. SP-3616, remove pinion locknut from
pinion shaft. If stub shaft is not held in place
while removing locknut, damage to the pinion teeth may result.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear Replacement > Page 5096
Fig. 6 Removing valve & pinion assembly
11. If only stub shaft seals are to be replaced, position tool No. L-4594-1-2-3 over stub shaft and
pull valve and pinion assembly out of valve housing
until flush with ball bearing assembly. Complete removal of valve and pinion assembly is not
necessary to replace stub shaft seals.
12. To remove valve and pinion assembly, rotate stub shaft until rack is centered in housing, with
pinion fully engaged. Mark position of stub shaft flat
on housing for reassembly. Using tool No. L-4594-1-2-3 pull valve and pinion assembly out of valve
housing. If necessary, remove valve body seal rings.
Fig. 7 Removing pinion shaft lower seal
13. Remove pinion shaft lower seal using seal remover No. C4694. 14. Remove pinion bearing
using a drift or punch, gently tap on bearing until bearing is removed.
Fig. 8 Removing inner rack oil seal
15. Remove inner rack seal from rack housing and dispose using tool No. C-4665. 16. Remove and
dispose of rack piston ring, inner rack seal, bulkhead seal and bulkhead O-ring. 17. Mark breather
tube to housing location and remove tube.
Assembly
1. Align breather tube with previously made marks on housing, then install grommet so tabs lock. 2.
Install new piston ring on rack, position seal protector No. C-4666 over rack teeth and slide seal
with lip facing piston onto rack. 3. Remove seal protector and bottom the seal on rack piston, slide
plastic retaining ring on rack onto seal. Slide rack, seal and piston ring into
housing, using caution not to rip or deform ring or seal. Tap rack with a rubber hammer to seat
seal. Do not attempt to remove upper pinion bushing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear Replacement > Page 5097
Fig. 9 Bulkhead oil seal installation
4. Coat all seals with automatic transmission fluid then, assemble new O-ring onto bulkhead
followed by new oil seal using tool No. C-4669. 5. Lubricate and install seat protector No. C-4670
or equivalent over rack threads, slide bulkhead assembly and end lock ring over seal protector,
O-ring end first and insert in rack tube, using caution not to rip or distort the O-ring.
Fig. 10 Installing bulkhead assembly into rack tube
6. Using tool No. C-4675, seat bulkhead in the rack tube. Install retaining wire by rotating bulkhead
assembly counterclockwise. Remove protective
tool.
Fig. 11 Pinion shaft seal installation
7. Install pinion shaft lower seal using tool No. C-4883. Then using a suitable socket, press in on
race of bearing, using caution not to cock bearing. 8. Install seal rings on valve body, if removed. 9.
Center rack in housing, then install pinion shaft and valve assembly so that flat on stub shaft will be
aligned with mark on housing when assembly
is fully seated.
Fig. 12 Stub shaft seal installation
10. Install stub shaft bearing then, position seal protector tool No. C-4668 or equivalent, slide shaft
seal over protector into valve housing. Seat seal
with seal installer No. C-4667 or equivalent and install retaining snap ring.
11. Install rack bearing, spring and adjuster plug. Turn adjuster plug until it bottoms, then back plug
off 40 to 60°. Install locknut and torque to 50 ft.
lbs. while holding adjuster plug in position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear Replacement > Page 5098
Fig. 13 Torquing inner tie rod pivot
12. Install tie rod assembly on rack. While holding rack in position with a wrench torque inner tie
rod pivot housing to 60 ft. lbs.. If rack is not held in
position while tightening tie rod housing, damage to the pinion teeth will result.
13. lubricate inner surfaces of bellows with silicone or other suitable lubricant. Align bellows marks
made previously with breather tube and install
bellows with boot seal over housing lip with hole in boot aligned with breather tube. Secure inner
clamp.
14. Position bellows outer clamp and jam nut on tie rod. Install tie rod end in the position as
removed. Torque jam nut to 55 ft. lbs., then install outer
bellows clamp. Ensure bellows is not twisted.
15. Rearm airbag system, refer to Air Bags and Seat Belts/Air Bags (Supplemental Restraint
Systems)/Service and Repair.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information >
Technical Service Bulletins > Customer Interest for Steering Shaft Coupler: > 190289 > Apr > 89 > Power Steering Gear `Hissing' Noise
Steering Shaft Coupler: Customer Interest Power Steering Gear - `Hissing' Noise
Models
1988-1989 A/AC, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, & S/AS Body Equipped With Power
Steering
Subject
Power Steering Gear "Hissing" Noise
Index
STEERING
Date
April 24, 1989
No.
19-02-89
(C19-03) BODY CODE LEGEND
AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU E CARAVELLE/600/NEW YORKER TURBO
G/AG - DAYTONA H/AH - LANCER/LeBARON GTS J/AJ - LeBARON (2-DOOR
COUPE/CONVERTIBLE) K/AK - ARIES/RELIANT/LeBARON (4-DOOR) TOWN & COUNTRY P/AP
- SHADOW/SUNDANCE S/AS - CARAVAN/VOYAGER/CARAVAN C/V
SYMPTOM/CONDITION
Power steering gear "hissing" noise evident inside the passenger compartment. The hissing noise
can be heard during quiet times in the vehicle while it is at rest with the engine running or while
negotiating low speed turns.
DIAGNOSIS
Operate the vehicle under the above conditions to verify the noise and that other components of
the steering gear system are operating properly. If all system components are OK then it will be
necessary to replace the steering column lower coupling to isolate the noise.
PARTS REQUIRED
1 Coupling Assembly PN 4470921
(A/AC, C/AC, E, G/AG, H/AH, J/AJ, K/AK, & P/AP Body)
1 Coupling Assembly (S/AS Body)
PN 4470915
REPAIR PROCEDURE
1. Remove the lower steering column coupling per the instructions in the appropriate
Front-Wheel-Drive Service Manual.
2. Replace the lower steering column coupling with the new one listed in the chart above.
3. Road test the vehicle to assure that the steering gear hissing noise is corrected.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.
19-20-12-90 . . . . . . . . . . . 1.0 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft Coupler: > 190289 > Apr > 89 > Power
Steering Gear - `Hissing' Noise
Steering Shaft Coupler: All Technical Service Bulletins Power Steering Gear - `Hissing' Noise
Models
1988-1989 A/AC, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, & S/AS Body Equipped With Power
Steering
Subject
Power Steering Gear "Hissing" Noise
Index
STEERING
Date
April 24, 1989
No.
19-02-89
(C19-03) BODY CODE LEGEND
AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU E CARAVELLE/600/NEW YORKER TURBO
G/AG - DAYTONA H/AH - LANCER/LeBARON GTS J/AJ - LeBARON (2-DOOR
COUPE/CONVERTIBLE) K/AK - ARIES/RELIANT/LeBARON (4-DOOR) TOWN & COUNTRY P/AP
- SHADOW/SUNDANCE S/AS - CARAVAN/VOYAGER/CARAVAN C/V
SYMPTOM/CONDITION
Power steering gear "hissing" noise evident inside the passenger compartment. The hissing noise
can be heard during quiet times in the vehicle while it is at rest with the engine running or while
negotiating low speed turns.
DIAGNOSIS
Operate the vehicle under the above conditions to verify the noise and that other components of
the steering gear system are operating properly. If all system components are OK then it will be
necessary to replace the steering column lower coupling to isolate the noise.
PARTS REQUIRED
1 Coupling Assembly PN 4470921
(A/AC, C/AC, E, G/AG, H/AH, J/AJ, K/AK, & P/AP Body)
1 Coupling Assembly (S/AS Body)
PN 4470915
REPAIR PROCEDURE
1. Remove the lower steering column coupling per the instructions in the appropriate
Front-Wheel-Drive Service Manual.
2. Replace the lower steering column coupling with the new one listed in the chart above.
3. Road test the vehicle to assure that the steering gear hissing noise is corrected.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.
19-20-12-90 . . . . . . . . . . . 1.0 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service
and Repair
Steering Wheel: Service and Repair
1. If equipped, disarm airbag system as described under MAINTENANCE PROCEDURES. 2.
Disconnect battery ground cable. 3. On column shift models, disconnect gearshift cable rod from
grommet in shift lever, then remove gearshift cable clip and cable from lower
bracket.
4. On all models, disconnect wiring connectors at steering column jacket. 5. Remove steering
wheel center pad assembly, then disconnect horn wire(s) and horn switch. 6. Remove steering
wheel nut. 7. On automatic transaxle models, remove damper assembly. 8. On all models, remove
steering wheel using puller No. C-3428B or equivalent. 9. Reverse procedure to install. Torque
steering wheel attaching nut to 45 ft. lbs. and rearm airbag system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Lower Ball Joint Replacement
Ball Joint: Service and Repair Lower Ball Joint Replacement
Fig. 6 Ball joint wear inspection
INSPECTION
With weight of vehicle resting on wheel and tire assembly, attempt to move grease fitting with
fingers. Do not use tool or added force to attempt to move grease fitting. If grease fitting moves
freely, ball joint is worn and should be replaced.
REPLACEMENT
The ball joint is pressed into the lower control arm. On these models, the ball joint may be pressed
from lower control arm using a 1-1/16 inch deep socket and ball joint installer tool No. C-4699-2 or
equivalent. When pressing ball joint into lower control arm, use ball joint installer tool Nos.
C-4699-1 and C-4699-2 or equivalents. Install ball joint seal using a 11* inch socket and ball joint
installer tool No. C-4699-2 or equivalent.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Lower Ball Joint Replacement > Page 5120
Ball Joint: Service and Repair Upper Ball Joint Replacement
Fig. 6 Ball joint wear inspection
INSPECTION
With weight of vehicle resting on wheel and tire assembly, attempt to move grease fitting with
fingers. Do not use tool or added force to attempt to move grease fitting. If grease fitting moves
freely, ball joint is worn and should be replaced.
REPLACEMENT
The ball joint is pressed into the lower control arm. On these models, the ball joint may be pressed
from lower control arm using a 1-1/16 inch deep socket and ball joint installer tool No. C-4699-2 or
equivalent. When pressing ball joint into lower control arm, use ball joint installer tool Nos.
C-4699-1 and C-4699-2 or equivalents. Install ball joint seal using a 11* inch socket and ball joint
installer tool No. C-4699-2 or equivalent.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service
and Repair
Control Arm: Service and Repair
Fig. 7 Lower control arm assembly
REMOVAL
1. Raise and support vehicle. 2. Remove front inner pivot through bolt, rear stub strut nut, retainer
and bushing, then the ball joint to steering knuckle clamp bolt. 3. Separate ball joint from steering
knuckle by prying between ball stud retainer and lower control arm. Pulling steering knuckle out
from vehicle
after releasing from ball joint can separate inner C/V joint.
4. Remove sway bar to control arm nut, then rotate control arm over sway bar. 5. Remove rear stub
strut bushing, sleeve and retainer. On AWD models, pivot bushings are not serviceable and must
be replaced as a unit.
INSTALLATION
1. Install retainer, bushing and sleeve on stub strut. 2. Position control arm over sway bar and
install rear stub strut and front pivot into crossmember. 3. Install front pivot bolt and loosely
assemble nut. 4. Install stub strut bushing and retainer and loosely assemble nut. 5. Install ball joint
stud into steering knuckle, then the clamp bolt. Tighten clamp bolt to specifications. 6. Place sway
bar end bushing retainer to control arm, then install retainer bolts. Tighten retainer bolts to
specifications. 7. Lower vehicle so suspension fully supports vehicle, then tighten front pivot bolt
and stub strut nut to specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Technical Service Bulletins > Customer Interest for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At
40-55 MPH
Cross-Member: Customer Interest Exhaust System - Drone At 40-55 MPH
Models
1987-90 S/AS Bodies With 2.5L & 3.0L Engines
Subject
Exhaust Drone At 40-55 MPH
Index
EXHAUST
Date
September 18, 1989
No.
11-02-89
(C11-01-9)
P-3455 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH).
DIAGNOSIS
Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from
under the floor pan area in front of the first bench seat. The vibration will also be present if the
engine is run through the 2350-2450 RPM range with the transmission in neutral.
PARTS REQUIRED
1 Crossmember Assembly PN 4427322
1 Muffler Support Bracket PN 4427295
1 Heat Shield PN 4401855
4 Screw & Washer Assembly PN 6501305
4 U-Nut PN 6101283
REPAIR PROCEDURE
1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the
exhaust insulators to remain on the muffler.
2. Remove the muffler support bracket, crossmember, and heat shield.
3. Install new heat shield, using the fasteners just removed.
4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250
+/- 50 in. lbs., washer should bottom out on sleeve.
5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN
6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs.
6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the
bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs.
7. Road test vehicle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Technical Service Bulletins > Customer Interest for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At
40-55 MPH > Page 5132
TIME ALLOWANCE: Labor Operation No.
11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 110289 > Sep > 89 > Exhaust System Drone At 40-55 MPH
Cross-Member: All Technical Service Bulletins Exhaust System - Drone At 40-55 MPH
Models
1987-90 S/AS Bodies With 2.5L & 3.0L Engines
Subject
Exhaust Drone At 40-55 MPH
Index
EXHAUST
Date
September 18, 1989
No.
11-02-89
(C11-01-9)
P-3455 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH).
DIAGNOSIS
Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from
under the floor pan area in front of the first bench seat. The vibration will also be present if the
engine is run through the 2350-2450 RPM range with the transmission in neutral.
PARTS REQUIRED
1 Crossmember Assembly PN 4427322
1 Muffler Support Bracket PN 4427295
1 Heat Shield PN 4401855
4 Screw & Washer Assembly PN 6501305
4 U-Nut PN 6101283
REPAIR PROCEDURE
1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the
exhaust insulators to remain on the muffler.
2. Remove the muffler support bracket, crossmember, and heat shield.
3. Install new heat shield, using the fasteners just removed.
4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250
+/- 50 in. lbs., washer should bottom out on sleeve.
5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN
6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs.
6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the
bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs.
7. Road test vehicle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 110289 > Sep > 89 > Exhaust System Drone At 40-55 MPH > Page 5138
TIME ALLOWANCE: Labor Operation No.
11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Fig. 9 Steering knuckle assembly
Fig. 10 Steering knuckle assembly
REMOVAL
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and driveshaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut.
Ensure splined driveshaft is free to separate from spline in hub during knuckle removal. A pulling
force on shaft can separate
inner C/V joint. Tap lightly with brass drift, if required.
5. Disconnect tie rod end from steering arm with a suitable puller. 6. Disconnect brake hose
retainer from strut damper. 7. Remove clamp bolt securing ball joint stud into steering knuckle, then
the brake caliper adapter screw and washer assemblies. 8. Support caliper with a piece of wire. Do
not hang by brake hose. 9. Remove rotor, then separate ball joint stud from knuckle assembly.
10. Remove knuckle assembly from vehicle. Support driveshaft during knuckle removal. Do not
permit driveshaft to hang after separating
steering knuckle from vehicle.
INSTALLATION
1. Place steering knuckle on lower ball joint stud and the driveshaft through hub. 2. Install and
tighten ball joint to steering knuckle clamp bolt to specifications. 3. Install tie rod end into steering
arm and tighten nut to specifications. Install cotter pin. 4. Install rotor. 5. Install caliper over rotor
and position adapter to steering knuckle. Install adapter to knuckle attaching bolts and tighten to
specifications. 6. Attach brake hose retainer to strut damper and tighten attaching screw to
specifications. 7. Install hub nut assembly as follows:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 5142
a. With brakes applied, install hub nut and tighten to specifications. b. Install spring washer, locknut
and new cotter pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component
Information > Service and Repair > Front
Stabilizer Bar: Service and Repair Front
Fig. 17 Sway bar assembly
REMOVAL
1. Raise and support vehicle. 2. Remove nuts, bolts and retainers at control armsshown, 3.
Remove crossmember clamp attaching bolts, then the crossmember clamps. 4. Remove sway bar
from vehicle.
INSTALLATION
1. Position crossmember bushings on sway bar with curved surface up and split to front of vehicle.
2. Position bar assembly onto crossmember, then install clamps and attaching boltsshown, 3.
Position retainers at control arms, then install bolts and attaching nuts. 4. Raise lower control arm
to correct position, then tighten attaching bolts to specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component
Information > Service and Repair > Front > Page 5147
Stabilizer Bar: Service and Repair Rear
Fig. 4 Rear sway bar assembly
REMOVAL
1. Raise and support vehicle. 2. Remove lower two sway bar to link arm retaining bolts on both
sides of vehicle. 3. Loosen, but do not remove four sway bar to bushing retainers to rear axle tube
brackets. 4. Hold sway bar in place, then remove four loose bolts and remove sway bar. Remove
link arms if needed.
INSTALLATION
1. If link arms were removed, install retaining nuts but do not tighten. 2. Position axle to sway bar
bushings on sway bar with slit in bushing facing up. 3. Install sway bar assembly onto rear axle but
do not tighten bolts. 4. Install two lower link arm bolts to sway bar but do nut tighten bolts. 5. Lower
vehicle, then tighten to specifications.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Front Shock Tower - Metal Screws/Bolts Precautions
Strut / Shock Tower: Technical Service Bulletins Front Shock Tower - Metal Screws/Bolts
Precautions
NO.: 02-08-92 GROUP: Suspension DATE: Dec. 14, 1992
SUBJECT: Installation Of Sheet Metal Screws Or Bolts Into The Front Shock Towers
MODELS:
1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 (AH) Lanced LeBaron GTS
1989 - 1993 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1990 (AQ) Horizon/Omni
1989 - 1993 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1991 (AQ) Chrysler's TC (Maserati Coupe)
1989 - 1993 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 (C) Dynasty/New Yorker
1984 - 1988 (E) Caravelle/600/New Yorker Turbo
1984 - 1988 (G) Daytona/Laser
1985 - 1988 (H) Lancer/LeBaron GTS
1987 - 1988 (J) LeBaron Coupe/LeBaron Convertible
1984 - 1988 (K) Reliant/Aries/LeBaron 4-Door/Town & Country
1984 - 1988 (L) Horizon/Omni
1987 - 1988 (P) Shadow/Sundance
1984 - 1988 (S) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
DISCUSSION:
It is very important that no sheet metal screws, bolts or other metal fasteners be installed in the
shock towers in place of plastic clips. Also, no holes should be drilled in the shock tower for
installation of any metal fasteners (see illustration, area "A").
Because of the minimum clearance in this area, installation of metal fasteners could damage the
coil spring coating. If a plastic clip is lost or broken, replace the clip with the equivalent part called
out in the appropriate Mopar Parts Catalog.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Front Shock Tower - Metal Screws/Bolts Precautions > Page 5152
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Specifications
Suspension Spring ( Coil / Leaf ): Specifications
Leaf Spring to Hanger Mounting Nut 105 ft.lb
Shackle Nuts 35 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Specifications > Page 5156
Suspension Spring ( Coil / Leaf ): Service and Repair
Fig. 5 Strut damper mount assembly
1. Remove strut damper assembly as previously described. 2. Compress coil spring using suitable
tool. 3. Remove strut rod nut while holding strut rod to prevent rotation. 4. Remove the mount
assembly. 5. Remove coil spring from strut damper. 6. Inspect mount assembly for deterioration of
rubber isolator, retainers for cracks and distortion, and bearings for blinding. 7. Install dust shield,
jounce bumper, spacer and seat to top of spring. Mount assembly to rod, then install retainer and
rod nut. 8. Position spring retainer alignment notch parallel to damper lower attaching bracket. 9.
Tighten strut rod nut to specifications, using suitable tool, then release spring compressor.
10. With weight of vehicle off front wheels, turn both strut rod and strut rod nut in same direction
until upper spring seat is properly positioned, then
recheck torque of strut rod nut.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications
Suspension Strut / Shock Absorber: Specifications
Shock Absorber Mounting Bolts Lower 80 ft.lb
Upper 85 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications > Page 5160
Suspension Strut / Shock Absorber: Service and Repair
REMOVAL
Fig. 3 Strut damper assembly removal
1. Raise and support vehicle, then remove front wheels. 2. Mark position of camber adjusting cam,
then remove camber adjusting bolt, through bolt and brake hose to damper bracket retaining
screw. 3. Remove strut damper to fender shield mounting nut and washer assemblies. 4. Remove
strut damper from vehicle.
INSTALLATION
Fig. 4 Strut damper assembly installation
1. Position strut assembly into fender reinforcement, then install retaining nut and washer
assemblies. Tighten retaining nut to specifications. 2. Position steering knuckle into strut, then
install washer plate, cam bolts and knuckle bolts. 3. Attach brake hose retainers to damper. Tighten
to specifications. 4. Index cam bolt to alignment mark made during removal. 5. Position a 4 inch or
larger C-clamp on steering knuckle and strut, then tighten clamp just enough to eliminate any
looseness between strut and
knuckle. Tighten cam bolts to specifications.
6. Remove C-clamp, then install wheel and tire assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications Nut Torque
Nut Torque
Front Axle Nut Torque 180 ft.lb
Rear Bearing Nut Torque 270 in.lb
+/- 30 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications > Page 5164
Wheel Bearing: Adjustments
Fig. 3 Wheel bearing assembly
1. Raise and support rear of vehicle.
2. Tighten adjusting nut to 27 to 34nm (240 to 300 in. lbs.) while rotating wheel.
3. Stop wheel and loosen adjusting nut.
4. Tighten adjusting nut finger tight. End play should be 0.0001-0.0020 inch.
5. Install castle lock with slots aligned with cotter pin hole.
6. Install cotter pin and grease cap.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front
Wheel Bearing: Service and Repair Front
Permanent Bearings
REMOVAL
Fig. 15 Removing hub & bearing assembly
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and drive shaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and
washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6.
Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the
caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor,
then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV
joint during this procedure.
Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported.
9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as
shown.
10. Remove hub and bearing assembly.
INSTALLATION
Fig. 16 Seal installation
1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using
oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of
seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse
driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve
using a suitable lubricant.
4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint
stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install
tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install
rotor, then position caliper over rotor and guide hold-down spring below machined guides on
knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut,
then with brakes applied, tighten nut to specifications.
10. Install spring washer, locknut and cotter pin.
Replaceable Bearings
REMOVAL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 5167
Fig. 14 Hub removal
Fig. 12 Removing bearing from knuckle
1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or
equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer.
4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle
using tool No. C-4811-2 or equivalent.
INSTALLATION
Fig. 13 Installing bearing into knuckle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 5168
Fig. 14 Installing hub into knuckle
1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer.
Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No.
C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No.
C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 5169
Wheel Bearing: Service and Repair Rear
REMOVAL
1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Remove cotter pin, nut
lock, spring washer and hub nut. 3. Remove half shaft flange retaining bolts. 4. Half shaft is spring
loaded, compress inner half shaft joint slightly pulling down to clear rear carrier output shaft. 5.
Remove half shaft by pulling half shaft assembly inboard. 6. Remove wheel bearing mounting
bolts, then wheel bearing and hub assembly. 7. Replace grease seal if needed.
INSTALLATION
1. If grease seal was removed, install a new seal using installer tool No. 6536-A or equivalent.
Lubricate circumference of seal before installation. 2. Install washer and hub nut. With brakes
applied, torque to 180 ft. lbs. 3. Install spring washer, nut lock and cotter pin. 4. Install hub and
bearing assembly. Torque bolts in a crossing pattern to 96 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Permanent Bearings
Wheel Hub: Service and Repair Permanent Bearings
REMOVAL
Fig. 15 Removing hub & bearing assembly
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and drive shaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and
washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6.
Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the
caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor,
then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV
joint during this procedure.
Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported.
9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as
shown.
10. Remove hub and bearing assembly.
INSTALLATION
Fig. 16 Seal installation
1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using
oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of
seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse
driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve
using a suitable lubricant.
4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint
stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install
tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install
rotor, then position caliper over rotor and guide hold-down spring below machined guides on
knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut,
then with brakes applied, tighten nut to specifications.
10. Install spring washer, locknut and cotter pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Permanent Bearings > Page 5174
Wheel Hub: Service and Repair Replaceable Bearings
REMOVAL
Fig. 14 Hub removal
Fig. 12 Removing bearing from knuckle
1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or
equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer.
4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle
using tool No. C-4811-2 or equivalent.
INSTALLATION
Fig. 13 Installing bearing into knuckle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and
Repair > Permanent Bearings > Page 5175
Fig. 14 Installing hub into knuckle
1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer.
Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No.
C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No.
C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire
Wear
Tires: All Technical Service Bulletins Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire
Wear > Page 5185
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire
Wear > Page 5186
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear
Tires: Customer Interest Rear Wheel Alignment - Uneven Tire Wear
NO.: 02-07-90
GROUP: SUSPENSION
DATE: Nov. 5, 1990
SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment
MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco)
SYMPTOM/CONDITION:
Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise.
DIAGNOSIS:
If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications.
Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2
wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack)
REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out
while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications.
PARTS REQUIRED:
1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies)
1 or 2 Shims PN 4626165 (all carlines)
Fig. 1-Shim Installation for Toe-Out
Fig. 2-Shim Installation for Toe-in
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page
5192
Fig. 3-Shim Installation for Positive Camber
Fig. 4-Shim Installation for Negative Camber
REPAIR PROCEDURES:
Installation of Rear Alignment Shims
1. Block front tires so vehicle will not move.
2. Release parking brake.
3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground.
4. Remove wheel and tire assembly.
5. Pry off grease cap.
6. Remove cotter pin and castle lock.
7. Remove brake drum/disc retaining nut.
8. Remove brake drum/disc.
9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim
installation. Do not remove mounting bolts.
10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3,
and 4) to bring the alignment as close as possible to the preferred camber and toe specifications.
Each shim changes alignment (camber or toe depending on shim installation position) by .3~.
11. Tighten four (4) brake assembly and spindle mounting bolts.
For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45
ft.lbs.)
12. Install brake drum/disc.
13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating
wheel. Back off adjusting nut with wrench to
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page
5193
completely release bearing preload. Finger tighten adjusting nut.
14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play
should be .025-mm. (.001-.003 in.). Clean and install grease cap.
15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque.
16. Lower vehicle.
17. Recheck alignment specifications.
The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS
REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS)
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications Nut Torque
Nut Torque
Front Axle Nut Torque 180 ft.lb
Rear Bearing Nut Torque 270 in.lb
+/- 30 in.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications > Page 5197
Wheel Bearing: Adjustments
Fig. 3 Wheel bearing assembly
1. Raise and support rear of vehicle.
2. Tighten adjusting nut to 27 to 34nm (240 to 300 in. lbs.) while rotating wheel.
3. Stop wheel and loosen adjusting nut.
4. Tighten adjusting nut finger tight. End play should be 0.0001-0.0020 inch.
5. Install castle lock with slots aligned with cotter pin hole.
6. Install cotter pin and grease cap.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front
Wheel Bearing: Service and Repair Front
Permanent Bearings
REMOVAL
Fig. 15 Removing hub & bearing assembly
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and drive shaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and
washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6.
Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the
caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor,
then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV
joint during this procedure.
Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported.
9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as
shown.
10. Remove hub and bearing assembly.
INSTALLATION
Fig. 16 Seal installation
1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using
oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of
seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse
driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve
using a suitable lubricant.
4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint
stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install
tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install
rotor, then position caliper over rotor and guide hold-down spring below machined guides on
knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut,
then with brakes applied, tighten nut to specifications.
10. Install spring washer, locknut and cotter pin.
Replaceable Bearings
REMOVAL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 5200
Fig. 14 Hub removal
Fig. 12 Removing bearing from knuckle
1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or
equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer.
4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle
using tool No. C-4811-2 or equivalent.
INSTALLATION
Fig. 13 Installing bearing into knuckle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 5201
Fig. 14 Installing hub into knuckle
1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer.
Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No.
C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No.
C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 5202
Wheel Bearing: Service and Repair Rear
REMOVAL
1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Remove cotter pin, nut
lock, spring washer and hub nut. 3. Remove half shaft flange retaining bolts. 4. Half shaft is spring
loaded, compress inner half shaft joint slightly pulling down to clear rear carrier output shaft. 5.
Remove half shaft by pulling half shaft assembly inboard. 6. Remove wheel bearing mounting
bolts, then wheel bearing and hub assembly. 7. Replace grease seal if needed.
INSTALLATION
1. If grease seal was removed, install a new seal using installer tool No. 6536-A or equivalent.
Lubricate circumference of seal before installation. 2. Install washer and hub nut. With brakes
applied, torque to 180 ft. lbs. 3. Install spring washer, nut lock and cotter pin. 4. Install hub and
bearing assembly. Torque bolts in a crossing pattern to 96 ft. lbs.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Permanent Bearings
Wheel Hub: Service and Repair Permanent Bearings
REMOVAL
Fig. 15 Removing hub & bearing assembly
1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub
and drive shaft are splined together through the knuckle (bearing) and retained by the hub
nut.
3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and
washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6.
Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the
caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor,
then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV
joint during this procedure.
Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported.
9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as
shown.
10. Remove hub and bearing assembly.
INSTALLATION
Fig. 16 Seal installation
1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using
oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of
seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse
driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve
using a suitable lubricant.
4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint
stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install
tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install
rotor, then position caliper over rotor and guide hold-down spring below machined guides on
knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut,
then with brakes applied, tighten nut to specifications.
10. Install spring washer, locknut and cotter pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Permanent Bearings > Page 5207
Wheel Hub: Service and Repair Replaceable Bearings
REMOVAL
Fig. 14 Hub removal
Fig. 12 Removing bearing from knuckle
1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or
equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer.
4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle
using tool No. C-4811-2 or equivalent.
INSTALLATION
Fig. 13 Installing bearing into knuckle
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Service and Repair > Permanent Bearings > Page 5208
Fig. 14 Installing hub into knuckle
1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer.
Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No.
C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No.
C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel Lug Nuts 95 ft.lb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations
Air Conditioning Switch: Locations
Lower I/P Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Adjustments
Air Door Cable: Adjustments
Temperature Control Cable
Position and hold the TEMP lever all the way to the left side of the control panel. Slide the self
adjusting clip toward the end of the cable, until the blend air door reaches its fully
counter-clockwise position. Move the cable from full left to full right several times checking for
smooth operation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Front End Components
Behind Center Of Grill
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair
Blower Motor: Service and Repair
REMOVAL AND INSTALLATION
1. Locate and disconnect the 2-way connector at the blower motor lead under the instrument panel
on the passenger side of the vehicle (the wire
connector insulator is wrapped with a foam silencer material).
2. Remove blower attaching (5) screws securing the blower to the heater-A/C unit. 3. Allow the
blower assembly to drop downward to clear the instrument panel, and remove the blower from the
vehicle.
To install, reverse the preceding operation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
Blower Motor Resistor: Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Service and Repair
Compressor Clutch: Service and Repair
REMOVAL
1. Remove a/c drive belt
2. Disconnect compressor clutch wires from the harness.
3. Remove compressor mounting bolts and lift compressor from its mounting bracket.
4. Rotate the compressor assembly to gain access to the front of the compressor clutch. Support
the compressor so that the weight of the compressor is not on the hoses. DO NOT let the
compressor hang from the hoses.
Front Plate Retaining Nut R&R; (VDC)
5. Use a 13mm socket and a spanner wrench to remove the shaft nut and lock washer.
6. Thread the front plate removal tool into the hub.
Front Plate R&R; (VDC)
7. Tighten the center bolt of the removal tool to pull off the front plate.
Front Plate Shims
8. Remove and save the shaft shim(s).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Service and Repair > Page 5233
A/C Pulley Snap Ring R&R;
9. Remove the pulley retaining snap ring with suitable snap ring pliers.
A/C Pulley R&R;
10. Slide the pulley off the compressor.
A/C Coil Snap Ring R&R;
11. Remove the coil retaining snap ring using suitable snap ring pliers.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Service and Repair > Page 5234
A/C Coil R&R;
12. Remove the screw that anchors the coil wires to the compressor housing. Remove the coil from
the compressor end plate.
INSTALLATION
A/C Coil Alignment
1. Align the hole in the back of the coil with the pin in the compressor end plate.
A/C Coil Snap Ring R&R;
2. Install the coil retaining snap ring with the beveled side facing outward and both of the snap ring
ends away from the alignment pin. Make sure the snap ring is properly seated in the groove.
3. Fasten the coil wires to the compressor housing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Service and Repair > Page 5235
A/C Pulley R&R;
4. Install the pulley and bearing assembly onto the compressor.
A/C Pulley Snap Ring R&R;
5. Install the pulley retaining snap ring with the beveled side outward. Make sure that the snap ring
is properly seated in the groove.
Front Plate Shims
6. Install the original shim(s) on the compressor shaft. If the original shims are not available, use a
temporary set of shims that equal 0.100 in (2.54 mm).
7. Install the front plate, making sure the key on the compressor shaft aligns with the keyway on the
front plate.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Service and Repair > Page 5236
Air Gap
8. Use a feeler gauge to measure the air gap between the front plate and the pulley face. The air
gap should be between 0.020 and 0.035 in. (0.05 and 0.9 mm.). If the air gap is incorrect, add or
remove shims on the compressor shaft to obtain the proper air gap.
Front Plate Retaining Nut R&R; (VDC)
9. Install lock washer and shaft nut. torque the shaft nut to 155 +/- 20 in.lbs. (17.5 +/- 2 N-m.).
10. Recheck the air gap after torquing the shaft and adjust shim thickness if necessary.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair
Compressor Clutch Coil: Service and Repair
REMOVAL
1. Remove a/c drive belt
2. Disconnect compressor clutch wires from the harness.
3. Remove compressor mounting bolts and lift compressor from its mounting bracket.
4. Rotate the compressor assembly to gain access to the front of the compressor clutch. Support
the compressor so that the weight of the compressor is not on the hoses. DO NOT let the
compressor hang from the hoses.
Front Plate Retaining Nut R&R; (VDC)
5. Use a 13mm socket and a spanner wrench to remove the shaft nut and lock washer.
6. Thread the front plate removal tool into the hub.
Front Plate R&R; (VDC)
7. Tighten the center bolt of the removal tool to pull off the front plate.
Front Plate Shims
8. Remove and save the shaft shim(s).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair > Page 5240
A/C Pulley Snap Ring R&R;
9. Remove the pulley retaining snap ring with suitable snap ring pliers.
A/C Pulley R&R;
10. Slide the pulley off the compressor.
A/C Coil Snap Ring R&R;
11. Remove the coil retaining snap ring using suitable snap ring pliers.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair > Page 5241
A/C Coil R&R;
12. Remove the screw that anchors the coil wires to the compressor housing. Remove the coil from
the compressor end plate.
INSTALLATION
A/C Coil Alignment
1. Align the hole in the back of the coil with the pin in the compressor end plate.
A/C Coil Snap Ring R&R;
2. Install the coil retaining snap ring with the beveled side facing outward and both of the snap ring
ends away from the alignment pin. Make sure the snap ring is properly seated in the groove.
3. Fasten the coil wires to the compressor housing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair > Page 5242
A/C Pulley R&R;
4. Install the pulley and bearing assembly onto the compressor.
A/C Pulley Snap Ring R&R;
5. Install the pulley retaining snap ring with the beveled side outward. Make sure that the snap ring
is properly seated in the groove.
Front Plate Shims
6. Install the original shim(s) on the compressor shaft. If the original shims are not available, use a
temporary set of shims that equal 0.100 in (2.54 mm).
7. Install the front plate, making sure the key on the compressor shaft aligns with the keyway on the
front plate.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair > Page 5243
Air Gap
8. Use a feeler gauge to measure the air gap between the front plate and the pulley face. The air
gap should be between 0.020 and 0.035 in. (0.05 and 0.9 mm.). If the air gap is incorrect, add or
remove shims on the compressor shaft to obtain the proper air gap.
Front Plate Retaining Nut R&R; (VDC)
9. Install lock washer and shaft nut. torque the shaft nut to 155 +/- 20 in.lbs. (17.5 +/- 2 N-m.).
10. Recheck the air gap after torquing the shaft and adjust shim thickness if necessary.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > A/C Compressor Clutch Cut-Out Relay
Compressor Clutch Relay: Locations A/C Compressor Clutch Cut-Out Relay
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > A/C Compressor Clutch Cut-Out Relay > Page 5248
Compressor Clutch Relay: Locations A/C Wide Open Throttle Cut-Out Relay
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Page 5249
Compressor Clutch Relay: Description and Operation
The A/C clutch relay is connected to the A/C damped pressure switch and the A/C switch. This
relay is in the On position during normal engine operation, but is closed when the SMEC senses
low idle speeds or wide open throttle conditions, preventing A/C clutch engagement.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information
> Locations
Condenser Fan Motor Relay: Locations
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Customer Interest for Control Assembly: > 241194 > Jul > 94 > A/C, Heater - Temperature
Lever Difficult to Move
Control Assembly: Customer Interest A/C, Heater - Temperature Lever Difficult to Move
NO: 24-11-94
GROUP: Heater & A/C
DATE: Jul. 1, 1994
SUBJECT: A/C Heater Blend Air Door Sticking
MODELS:
1989 - 1994 (AS) Town & Country/Caravan/Voyager 1984 - 1988 (S) Caravan/Voyager
SYMPTOM/CONDITION:
Poor heater performance, or poor A/C performance, and/or temperature control lever difficult or
impossible to move.
DIAGNOSIS:
Check the temperature control lever for a binding condition. If the lever is difficult or impossible to
move, perform the repair procedure.
PARTS REQUIRED:
AR 4318039 Mopar Rust Penetrant
AR 4318066 Mopar White Spray Lube
REPAIR PROCEDURE:
This bulletin involves accessing the lower pivot and contact surfaces of the blend air door shaft to
apply rust penetrant to free up the shaft and then apply lubricant to prevent further corrosion.
1. Remove the center floor console on vehicles so equipped.
2. Remove the floor air distribution duct.
3. On the extension which houses the blend air door shaft inside the heater-A/C housing (Refer to
Illustration), drill a 3/32 in. (2.2 mm) hole perpendicular to the side of the extension and 3/8 in. (10
mm) up from the bottom of the extension to gain access to the blend air door shaft.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Customer Interest for Control Assembly: > 241194 > Jul > 94 > A/C, Heater - Temperature
Lever Difficult to Move > Page 5261
4. Spray a sufficient amount of Mopar Rust Penetrant into the hole drilled in step 3 and work the
temperature control lever until it moves freely.
5. When the door moves freely, inject Mopar White Spray Lube into the hole for two seconds time
in order to prevent further binding/sticking in this area.
6. Wipe the housing exterior clean of any excess lubricant and tape over hole in extension with
black duct tape.
7. Install floor air distribution duct.
8. Install center floor console if equipped.
9. If movement of the temperature control lever is still difficult, inspect the temperature control cable
where it attaches to the control for kinks. If kinked replace the temperature control cable. Refer to
the appropriate service manual for cable replacement procedure, and the appropriate Labor
Operation Time Schedule Manual for cable replacement time allowance.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
1984 - 1993 24-65-20-90 0.4 Hrs.
1994 24-65-20-91 0.6 Hrs.
Center Floor Console (if Equipped) 24-65-20-60 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 241194 > Jul > 94 > A/C, Heater Temperature Lever Difficult to Move
Control Assembly: All Technical Service Bulletins A/C, Heater - Temperature Lever Difficult to
Move
NO: 24-11-94
GROUP: Heater & A/C
DATE: Jul. 1, 1994
SUBJECT: A/C Heater Blend Air Door Sticking
MODELS:
1989 - 1994 (AS) Town & Country/Caravan/Voyager 1984 - 1988 (S) Caravan/Voyager
SYMPTOM/CONDITION:
Poor heater performance, or poor A/C performance, and/or temperature control lever difficult or
impossible to move.
DIAGNOSIS:
Check the temperature control lever for a binding condition. If the lever is difficult or impossible to
move, perform the repair procedure.
PARTS REQUIRED:
AR 4318039 Mopar Rust Penetrant
AR 4318066 Mopar White Spray Lube
REPAIR PROCEDURE:
This bulletin involves accessing the lower pivot and contact surfaces of the blend air door shaft to
apply rust penetrant to free up the shaft and then apply lubricant to prevent further corrosion.
1. Remove the center floor console on vehicles so equipped.
2. Remove the floor air distribution duct.
3. On the extension which houses the blend air door shaft inside the heater-A/C housing (Refer to
Illustration), drill a 3/32 in. (2.2 mm) hole perpendicular to the side of the extension and 3/8 in. (10
mm) up from the bottom of the extension to gain access to the blend air door shaft.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 241194 > Jul > 94 > A/C, Heater Temperature Lever Difficult to Move > Page 5267
4. Spray a sufficient amount of Mopar Rust Penetrant into the hole drilled in step 3 and work the
temperature control lever until it moves freely.
5. When the door moves freely, inject Mopar White Spray Lube into the hole for two seconds time
in order to prevent further binding/sticking in this area.
6. Wipe the housing exterior clean of any excess lubricant and tape over hole in extension with
black duct tape.
7. Install floor air distribution duct.
8. Install center floor console if equipped.
9. If movement of the temperature control lever is still difficult, inspect the temperature control cable
where it attaches to the control for kinks. If kinked replace the temperature control cable. Refer to
the appropriate service manual for cable replacement procedure, and the appropriate Labor
Operation Time Schedule Manual for cable replacement time allowance.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
1984 - 1993 24-65-20-90 0.4 Hrs.
1994 24-65-20-91 0.6 Hrs.
Center Floor Console (if Equipped) 24-65-20-60 0.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 5268
Control Assembly: Locations
Lower I/P Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement
Evaporator Core: Service and Repair Evaporator Core Replacement
REMOVAL
1. Drain cooling system and discharge A/C system, if equipped. See: Service and
Repair/Refrigerant Recovery 2. Disconnect vacuum line at brake booster. If equipped, disconnect
vacuum line at water valve. 3. Disconnect heater hoses at heater core. Plug heater core tubes to
prevent spilling coolant.
Expansion Valve
4. On models with A/C, disconnect A/C plumbing at expansion valve and remove the expansion
valve from the evaporator.
Resistor Block And Drain Tube
5. Remove the condensate drain tube. 6. On all models, remove 4 nuts from unit mounting studs.
7. Remove steering column cover from left lower instrument panel. 8. Remove lower reinforcement
from below steering column. 9. Remove right side cowl and sill trim.
10. Remove bolt attaching right side instrument panel to right cowl.
11. Loosen two brackets supporting lower edge of instrument panel to A/C and heater or heater
housing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 5273
Instrument Panel Assembly
12. Remove the instrument panel trim moulding from the right side dash panel.
13. Remove the nine screws that attach the lower instrument panel to the upper instrument panel.
14. Carefully pull the right side of lower instrument panel rearward until it reaches passenger seat.
15. Disconnect the blower motor and resistor electrical connectors and temperature control cable.
16. Disconnect hanger strap from evaporator heater assembly and bend rearward.
17. Pull heater-a/c assembly rearward from dash panel and remove from vehicle.
18. Place heater-a/c assembly on workbench, then remove vacuum harness attaching screw. Feed
harness through hole in cover.
19. Remove thirteen cover attaching screws, then the cover. Temperature control door will come
out with cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 5274
Fig. 15 Evaporator heater assembly
20. Remove heater core tube retaining bracket attaching screw, then lift the heater core straight up.
21. Lift evaporator up and out of unit.
22. Remove sound shield attaching screws, then blower motor assembly.
INSTALLATION
Fig. 15 Evaporator heater assembly
1. Install the blower motor and sound shield.
2. Install the evaporator to the heater-a/c housing.
3. Install the heater core and secure with one screw through the attaching bracket.
4. Install the top cover, making sure the blend-air door is properly located in the bottom of the
heater-a/c housing. Secure top cover with 13 screws.
5. Feed the vacuum harness through the hole and secure with one screw.
6. Slide the heater-a/c unit under the lower right instrument panel. Feed the vacuum hoses through
the hole in the firewall.
7. Raise and install the heater-a/c unit to the firewall, making sure the mounting studs go
completely through and the vacuum hoses are not pinched.
8. Secure the heater-a/c unit with one screws through the hangar strap and four nuts on the
mounting studs.
9. Attach the temperature control cable, blower motor wiring, and resistor wiring.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 5275
Instrument Panel Assembly
10. Position the right lower instrument panel and attach with 9 screws through the upper instrument
panel and one bolt in the right side cowl.
11. Reinstall instrument panel trim moulding.
12. Reattach all previously removed dash wiring.
13. Install steering column reinforcement, lower steering column cover and right cowl and sill trim
panels.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 5276
Resistor Block And Drain Tube
14. Install the condensate drain tube.
15. Connect the vacuum hoses to the engine and water valve.
16. Connect the heater hoses and refill the engine coolent system.
Expansion Valve
17. Connect the expansion valve to the evaporator with a new gasket. Torque the torx head screws
to 100 +/- 30 in.lbs. (11 +/- 3 N-m.).
18. Connect the a/c plumbing to the expansion valve. Torque the bolt to 200 +/- 30 in.lbs. (23 +/- 3
N-m.).
19. Evacuate and recharge the a/c system.
20. Test system for overall performance.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Evaporator Core Replacement > Page 5277
Evaporator Core: Service and Repair Rear Evaporator and Expansion Valve Replacement
REMOVAL
1. Remove rear heat-a/c unit.See: Housing Assembly HVAC/Service and Repair
2. Remove rear unit top cover.
3. Remove the evaporator by carefully lifting it straight up and out of the rear unit.
4. Remove the two 1/4-20 torx head screws that anchor the expansion valve to the evaporator.
5. Measure and record the amount of refrigeration oil removed from the evaporator.
INSTALLATION
1. Replace the amount of refrigeration oil previously measured with clean oil.
2. Attach the expansion valve to the evaporator with a new gasket. Torque the torx head screws to
100 +/- 30 in.lbs. (11 +/- 3 N-m.).
3. Install the evaporator into the rear heat-a/c unit.
4. Install the rear unit top cover.
5. Install the rear unit in the vehicle.See: Housing Assembly HVAC/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair
Expansion Valve: Service and Repair
REMOVAL
1. Remove rear heat-a/c unit.See: Housing Assembly HVAC/Service and Repair
2. Remove rear unit top cover.
3. Remove the evaporator by carefully lifting it straight up and out of the rear unit.
4. Remove the two 1/4-20 torx head screws that anchor the expansion valve to the evaporator.
5. Measure and record the amount of refrigeration oil removed from the evaporator.
INSTALLATION
1. Replace the amount of refrigeration oil previously measured with clean oil.
2. Attach the expansion valve to the evaporator with a new gasket. Torque the torx head screws to
100 +/- 30 in.lbs. (11 +/- 3 N-m.).
3. Install the evaporator into the rear heat-a/c unit.
4. Install the rear unit top cover.
5. Install the rear unit in the vehicle.See: Housing Assembly HVAC/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Blower Motor, Evaporator & Heater Core
Heater Core: Service and Repair Blower Motor, Evaporator & Heater Core
REMOVAL
1. Drain cooling system and discharge A/C system, if equipped. See: Service and
Repair/Refrigerant Recovery 2. Disconnect vacuum line at brake booster. If equipped, disconnect
vacuum line at water valve. 3. Disconnect heater hoses at heater core. Plug heater core tubes to
prevent spilling coolant.
Expansion Valve
4. On models with A/C, disconnect A/C plumbing at expansion valve and remove the expansion
valve from the evaporator.
Resistor Block And Drain Tube
5. Remove the condensate drain tube. 6. On all models, remove 4 nuts from unit mounting studs.
7. Remove steering column cover from left lower instrument panel. 8. Remove lower reinforcement
from below steering column. 9. Remove right side cowl and sill trim.
10. Remove bolt attaching right side instrument panel to right cowl. 11. Loosen two brackets
supporting lower edge of instrument panel to A/C and heater or heater housing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Blower Motor, Evaporator & Heater Core > Page 5285
Instrument Panel Assembly
12. Remove the instrument panel trim moulding from the right side dash panel. 13. Remove the
nine screws that attach the lower instrument panel to the upper instrument panel. 14. Carefully pull
the right side of lower instrument panel rearward until it reaches passenger seat. 15. Disconnect
the blower motor and resistor electrical connectors and temperature control cable. 16. Disconnect
hanger strap from evaporator heater assembly and bend rearward. 17. Pull heater-a/c assembly
rearward from dash panel and remove from vehicle. 18. Place heater-a/c assembly on workbench,
then remove vacuum harness attaching screw. Feed harness through hole in cover. 19. Remove
thirteen cover attaching screws, then the cover. Temperature control door will come out with cover.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Blower Motor, Evaporator & Heater Core > Page 5286
Fig. 15 Evaporator heater assembly
20. Remove heater core tube retaining bracket attaching screw, then lift the heater core straight up.
21. Lift evaporator up and out of unit. 22. Remove sound shield attaching screws, then blower
motor assembly.
INSTALLATION
Fig. 15 Evaporator heater assembly
1. Install the blower motor and sound shield.
2. Install the evaporator to the heater-a/c housing.
3. Install the heater core and secure with one screw through the attaching bracket.
4. Install the top cover, making sure the blend-air door is properly located in the bottom of the
heater-a/c housing. Secure top cover with 13 screws.
5. Feed the vacuum harness through the hole and secure with one screw.
6. Slide the heater-a/c unit under the lower right instrument panel. Feed the vacuum hoses through
the hole in the firewall.
7. Raise and install the heater-a/c unit to the firewall, making sure the mounting studs go
completely through and the vacuum hoses are not pinched.
8. Secure the heater-a/c unit with one screws through the hangar strap and four nuts on the
mounting studs.
9. Attach the temperature control cable, blower motor wiring, and resistor wiring.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Blower Motor, Evaporator & Heater Core > Page 5287
Instrument Panel Assembly
10. Position the right lower instrument panel and attach with 9 screws through the upper instrument
panel and one bolt in the right side cowl.
11. Reinstall instrument panel trim moulding.
12. Reattach all previously removed dash wiring.
13. Install steering column reinforcement, lower steering column cover and right cowl and sill trim
panels.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Blower Motor, Evaporator & Heater Core > Page 5288
Resistor Block And Drain Tube
14. Install the condensate drain tube.
15. Connect the vacuum hoses to the engine and water valve.
16. Connect the heater hoses and refill the engine coolent system.
Expansion Valve
17. Connect the expansion valve to the evaporator with a new gasket. Torque the torx head screws
to 100 +/- 30 in.lbs. (11 +/- 3 N-m.).
18. Connect the a/c plumbing to the expansion valve. Torque the bolt to 200 +/- 30 in.lbs. (23 +/- 3
N-m.).
19. Evacuate and recharge the a/c system.
20. Test system for overall performance.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Blower Motor, Evaporator & Heater Core > Page 5289
Heater Core: Service and Repair Heater Core Removal and Installation
1. Remove rear heat-a/c unit.See: Housing Assembly HVAC/Service and Repair
2. Remove rear unit top cover.
3. Remove the heater core by carefully lifting it straight up and out of the rear unit.
4. Reverse procedure to reinstall.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > Customer Interest for Hose/Line HVAC: > 240395 > Jan > 95 > A/C System - Poor Cooling Performance
Hose/Line HVAC: Customer Interest A/C System - Poor Cooling Performance
NO: 24-03-95
GROUP: Heater & A/C
DATE: Jan. 27, 1995
SUBJECT: Revised Underbody Refrigerant Line Gasket
MODELS:
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1992 - 1995 (ES) Chrysler Voyager (European Market)
1989 (S) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH
AUXILIARY REAR A/C OPTION.
SYMPTOM/CONDITION:
Poor A/C system cooling performance.
DIAGNOSIS:
Check for low refrigerant charge and inspect the connection of the A/C underbody refrigerant lines
to the rear auxiliary A/C unit. If refrigerant is detected at the connection, perform the repair
procedure.
PARTS REQUIRED:
1 4798270 Gasket, Underbody Refrigerant Line
REPAIR PROCEDURE:
This bulletin involves installing a revised underbody refrigerant line gasket.
1. Recover any residual refrigerant in the A/C system.
2. Disconnect the A/C underbody refrigerant lines from the rear auxiliary A/C unit.
3. Inspect and clean the A/C plumbing surfaces that contact the gasket. Do not scratch the
surfaces.
4. Install the revised gasket, P/N 4798270. This gasket is rubber coated stainless steel.
5. Evacuate and recharge the A/C system using the procedure outlined in the appropriate Service
Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-45-62-90 .......................................................................................................
................................................................ 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > Customer Interest for Hose/Line HVAC: > 240490 > Sep > 90 > Air Conditioning System Moaning/Growling Noise
Hose/Line HVAC: Customer Interest Air Conditioning System - Moaning/Growling Noise
NO.: 24-04-90
GROUP: HEATER & A/C
DATE: Sept. 10, 1990
SUBJECT: Air Conditioning
System Noise - 3.OL Engine
MODELS: 1989 Dodge Caravan, Grand Caravan, Caravan C/V, Plymouth Voyager, Grand
Voyager, Chrysler Town & Country
SYMPTOM/CONDITION
Some vehicles equipped with the 3.OL engine may exhibit a moaning or growling noise when the
air conditioning system is on. This noise is caused by refrigerant gas pulsation being transmitted
through the A/C discharge line. This noise is NOT the fault of the A/C compressor.
DIAGNOSIS
Verify that the vehicle has a moaning or growling noise when the air conditioning is on. Inspect the
entire length of the discharge, suction and liquid lines for grounding. These lines should not touch
any sheet metal or underhood component. Also inspect these lines for grounding during engine roll
and where the lines go through the bulkhead. Inspect for proper foam or rubber isolation at all
brackets and the radiator support and correct as necessary. If the noise persists, proceed to the
following repair procedure. Remember, the compressor should not be replaced unless it has failed
the output test outlined in TSB 24-03-89 Revision A or is making metallic noises. REPLACING THE
COMPRESSOR FOR THE A/C DISCHARGE LINE NOISE WILL NOT CORRECT THE PROBLEM.
PARTS REQUIRED
1 4419464 A/C Discharge Line Assembly
REPAIR PROCEDURE
This procedure involves inspection and replacement of the A/C discharge line assembly with a
revised discharge line.
1. Check to see if the A/C discharge line muffler is approximately two inches from the condenser. If
so, remove the discharge line according to the procedure outlined in the service manual.
A/C systerns should be evacuated using an approved recovery station.
2. Install a new discharge line assembly (PN 4419464) that has a muffler located near the
compressor attachment flange.
3. Verify A/C operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
24-45-25-91 . . . . . . . . . . . . . . . . 1.2 Hrs.
Replace A/C Discharge Line Assembly
24-01-10-01 . . . . . . . . . . . . . . . . 0.2 Hrs. Additional Time Required When R12 Recovery Station Is
Used
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 240395 > Jan > 95 > A/C System - Poor Cooling
Performance
Hose/Line HVAC: All Technical Service Bulletins A/C System - Poor Cooling Performance
NO: 24-03-95
GROUP: Heater & A/C
DATE: Jan. 27, 1995
SUBJECT: Revised Underbody Refrigerant Line Gasket
MODELS:
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1992 - 1995 (ES) Chrysler Voyager (European Market)
1989 (S) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH
AUXILIARY REAR A/C OPTION.
SYMPTOM/CONDITION:
Poor A/C system cooling performance.
DIAGNOSIS:
Check for low refrigerant charge and inspect the connection of the A/C underbody refrigerant lines
to the rear auxiliary A/C unit. If refrigerant is detected at the connection, perform the repair
procedure.
PARTS REQUIRED:
1 4798270 Gasket, Underbody Refrigerant Line
REPAIR PROCEDURE:
This bulletin involves installing a revised underbody refrigerant line gasket.
1. Recover any residual refrigerant in the A/C system.
2. Disconnect the A/C underbody refrigerant lines from the rear auxiliary A/C unit.
3. Inspect and clean the A/C plumbing surfaces that contact the gasket. Do not scratch the
surfaces.
4. Install the revised gasket, P/N 4798270. This gasket is rubber coated stainless steel.
5. Evacuate and recharge the A/C system using the procedure outlined in the appropriate Service
Manual.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-45-62-90 .......................................................................................................
................................................................ 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 240490 > Sep > 90 > Air Conditioning System Moaning/Growling Noise
Hose/Line HVAC: All Technical Service Bulletins Air Conditioning System - Moaning/Growling
Noise
NO.: 24-04-90
GROUP: HEATER & A/C
DATE: Sept. 10, 1990
SUBJECT: Air Conditioning
System Noise - 3.OL Engine
MODELS: 1989 Dodge Caravan, Grand Caravan, Caravan C/V, Plymouth Voyager, Grand
Voyager, Chrysler Town & Country
SYMPTOM/CONDITION
Some vehicles equipped with the 3.OL engine may exhibit a moaning or growling noise when the
air conditioning system is on. This noise is caused by refrigerant gas pulsation being transmitted
through the A/C discharge line. This noise is NOT the fault of the A/C compressor.
DIAGNOSIS
Verify that the vehicle has a moaning or growling noise when the air conditioning is on. Inspect the
entire length of the discharge, suction and liquid lines for grounding. These lines should not touch
any sheet metal or underhood component. Also inspect these lines for grounding during engine roll
and where the lines go through the bulkhead. Inspect for proper foam or rubber isolation at all
brackets and the radiator support and correct as necessary. If the noise persists, proceed to the
following repair procedure. Remember, the compressor should not be replaced unless it has failed
the output test outlined in TSB 24-03-89 Revision A or is making metallic noises. REPLACING THE
COMPRESSOR FOR THE A/C DISCHARGE LINE NOISE WILL NOT CORRECT THE PROBLEM.
PARTS REQUIRED
1 4419464 A/C Discharge Line Assembly
REPAIR PROCEDURE
This procedure involves inspection and replacement of the A/C discharge line assembly with a
revised discharge line.
1. Check to see if the A/C discharge line muffler is approximately two inches from the condenser. If
so, remove the discharge line according to the procedure outlined in the service manual.
A/C systerns should be evacuated using an approved recovery station.
2. Install a new discharge line assembly (PN 4419464) that has a muffler located near the
compressor attachment flange.
3. Verify A/C operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE Labor Operation No.
24-45-25-91 . . . . . . . . . . . . . . . . 1.2 Hrs.
Replace A/C Discharge Line Assembly
24-01-10-01 . . . . . . . . . . . . . . . . 0.2 Hrs. Additional Time Required When R12 Recovery Station Is
Used
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair
Housing Assembly HVAC: Service and Repair
Rear Heater-A/C Components
REMOVAL
1. Discharge the A/C system.See: Service and Repair/Refrigerant Recovery
2. Drain the engine coolent.
Rear Heater Plumbing
3. Disconnect the rear heater hoses at the rear heater-a/c unit. Plug the heater core tubes to
prevent spilling.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Page 5314
Rear A/C Plumbing
4. Disconnect the a/c plumbing at the rear heat-a/c unit.
5. Remove the left rear quarter trim panels.
6. Remove the attaching screws at the air distribution duct.
7. Remove the attaching screws that anchor the rear heat-a/c unit to the floor and the quarter panel
support.
8. Lift the unit up and remove it from the car.
INSTALLATION
1. Place the rear heat-a/c unit in the vehicle and anchor to the floor and the quarter panel support
with original screws.
2. Install air distribution duct.
3. Install rear coolent hoses and refill engine coolent system.
4. Install rear a/c lines using new gaskets.
5. Evacuate and recharge a/c system.See: Service and Repair/Refrigerant System Evacuate
6. Test for leaks and overall performance of system.
7. Install left rear quarter trim panels.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > A/C
System
Refrigerant: Specifications A/C System
REFRIGERANT CAPACITIES
DODGE/PLYMOUTH TRUCKS
1992 Ram 50 pickup ............................................................................................................................
.............................................. 0.8 kg (30 oz.) Ramcharger ..................................................................
............................................................................................................. 1.3 kg (44 oz.)
1992-91 Dakota ...................................................................................................................................
................................................... 1.2 kg (40 oz.) B-Series van ............................................................
.................................................................................................................. 1.3 kg (44 oz.) with rear
unit .......................................................................................................................................................
...................... 1.8 kg (62 oz.)
1992-90 Caravan, Mini Ram, Voyager
................................................................................................................................................... 0.9 kg
(32 oz.) with rear unit ...........................................................................................................................
.................................................. 1.2 kg (43 oz.)
1992-88 D/W-Series pickup .................................................................................................................
.................................................. 1.3 kg (44 oz.)
1990-87 Dakota ...................................................................................................................................
................................................... 1.3 kg (44 oz.)
1990-83 B-Series van ..........................................................................................................................
.................................................... 1.4 kg (48 oz.) with rear unit ...........................................................
.................................................................................................................. 1.8 kg (62 oz.)
1989-84 Caravan, Mini-Ram, Voyager
................................................................................................................................................... 1.1 kg
(38 oz.) with rear AC ............................................................................................................................
................................................. 1.3 kg (44 oz.)
1987-83 D/W-Series pickup .................................................................................................................
.................................................. 1.1 kg (40 oz.)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > A/C
System > Page 5319
Refrigerant: Specifications Capacities
Capacities
Capacity
2.38 lb (US)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > A/C
System > Page 5320
Refrigerant: Specifications Capacities
Capacities
Capacity
2.70 lb (US)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications
Fig. 10 A/C Component Oil Capacity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair
> Oil Charge Additions
Refrigerant Oil: Service and Repair Oil Charge Additions
If there are no signs of external oil leakage, proceed as follows to add oil to system during
component replacement.
1. Discharge system refer to, Heating and Air Conditioning/Service and Repair and measure
amount of oil collected in discharge container. The amount of oil collected when discharging
system must be replaced with new refrigeration oil to maintain proper oil charge.
2. Remove defective components. Measure amount of oil remaining in compressor, if removed.
3. Add correct amount of oil to components. Refer to Air Conditioning/Specifications/Capacities.
4. Install replacement components, then evacuate and recharge system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair
> Oil Charge Additions > Page 5326
Refrigerant Oil: Service and Repair Refrigerant Oil Level Check
Compressor oil level need only be checked when there is evidence of oil loss from the system as in
the case of a broken line, leaking fitting or component, defective compressor seal or collision
damage to system. A wet, shiny surface around a leak point is evidence of oil loss.
These compressors must be removed from vehicle and drained to check the oil level, proceed as
follows: 1. Discharge system refer to, DISCHARGING & EVACUATING SYSTEM, and repair leak
as necessary. 2. Disconnect suction and discharge lines from compressor, then remove
compressor and clutch assembly from vehicle. 3. Invert compressor and drain oil through suction
and discharge ports. 4. Determine the correct amount of oil to add to compressor by subtracting the
amount of oil remaining in other components. Refer to . 5. On all models, add oil to compressor
through suction port. 6. Reinstall compressor using new gaskets on refrigerant line fittings, then
evacuate and recharge system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations
High Pressure Sensor / Switch: Locations
Engine Components.
A/C High Pressure Switch located at rear Of A/C Clutch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Locations
Low Pressure Sensor / Switch: Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > A/C Compressor Clutch Cut-Out Relay
Compressor Clutch Relay: Locations A/C Compressor Clutch Cut-Out Relay
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > A/C Compressor Clutch Cut-Out Relay > Page 5339
Compressor Clutch Relay: Locations A/C Wide Open Throttle Cut-Out Relay
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 5340
Compressor Clutch Relay: Description and Operation
The A/C clutch relay is connected to the A/C damped pressure switch and the A/C switch. This
relay is in the On position during normal engine operation, but is closed when the SMEC senses
low idle speeds or wide open throttle conditions, preventing A/C clutch engagement.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay,
HVAC > Component Information > Locations
Condenser Fan Motor Relay: Locations
Engine Compartment Components.
On LH Fender Apron
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Locations
Air Conditioning Switch: Locations
Lower I/P Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor
/ Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Front End Components
Behind Center Of Grill
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
High Pressure Sensor / Switch: Locations
Engine Components.
A/C High Pressure Switch located at rear Of A/C Clutch
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations
Low Pressure Sensor / Switch: Locations
Engine Compartment Components.
RH Rear Corner Of Engine Compartment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations
Fig. 11 Charging Valve Location
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag System Arming and Disarming
1. Place ignition switch in lock position.
2. Disconnect and tape battery ground cable connector.
3. Wait at least 1 minute after disconnecting battery ground cable before performing any further
repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a
short time even after battery has been disconnected.
4. After repairs are performed, connect battery ground cable.
5. From passenger side of vehicle, turn ignition switch to On position.
6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to
indicate if SRS system is functioning correctly.
7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations
Fig. 45 Airbag system diagnostic module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Fig. 45 Airbag system diagnostic module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag System Arming and Disarming
1. Place ignition switch in lock position.
2. Disconnect and tape battery ground cable connector.
3. Wait at least 1 minute after disconnecting battery ground cable before performing any further
repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a
short time even after battery has been disconnected.
4. After repairs are performed, connect battery ground cable.
5. From passenger side of vehicle, turn ignition switch to On position.
6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to
indicate if SRS system is functioning correctly.
7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation
Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether
Installation
NUMBER: 23-029-08
GROUP: Body
DATE: October 24, 2008
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED
NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR
MILEAGE.
SUBJECT: Child Seat Tether Anchor Installation
OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on
Customer Request.
NOTE:
Dealers are encouraged to honor any customers request for the installation of the Child Seat
Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or
mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for
reimbursement detail.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shawdow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5382
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
2000 (TJ) Wrangler
1999 - 2000 (WJ) Grand Cherokee
1989 - 2000 (XJ) Cherokee/Wagoneer
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve
the performance of child restraints in collisions. Because of the publicity that has accompanied the
"Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware.
Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether
anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet.
NOTE:
This bulletin is provided to identify the parts and labor operation numbers necessary to install a
Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer
request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits
regardless of vehicle age or mileage.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5383
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5384
PARTS REQUIRED:
POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5385
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5386
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5387
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5388
Technical Service Bulletin # 232288 Date: 881230
Child Seat Anchor - Installation
Models
1989 AA-, AC-, AG-, AH-, AJ-, AK-, AL-, AM-, AP-, & BB-Body Passenger Car
AB- & AS-Body Truck (See Body Code Legend)
Subject
Child Seat Tether Anchor Installation
Index
BODY
Date
December 30, 1988
No.
23-22-88
P-5444 (C23-11) BODY CODE LEGEND
Passenger Cars
AA - Spirit Acclaim AC - Dynasty/New Yorker/Landau AG - Daytona AH - Lancer/LeBaron GTS AJ
- LeBaron (2-Door Coupe/Convertible) AK - Aries/Reliant AL - Omni/Horizon AM Diplomat/Newport/Fifth Avenue AP - Shadow/Sundance BB - Premier
Trucks
AB - Dodge Ram Van/Wagon (Rear-Wheel-Drive) AS - Caravan/Voyager
Due to increased customer interest, child seat tether anchor packages have been made available.
Upon customer request, the appropriate vehicle package and install according to attached
instructions.
POLICY: Information Only - These packages to be installed at the customer's expense.
Pkg. No. 4519077
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5389
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5390
INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE
CHRYSLER LEBARON, PLYMOUTH CARAVELLE SALON AND
DODGE DIPLOMAT SALON AND
DIPLOMAT S.E., CHRYSLER NEWPORT AND FIFTH AVENUE
EAGLE PREMIER, DODGE ARIES AND PLYMOUTH RELIANT INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519077
CHILD SEAT TETHER ANCHORAGE
CHRYSLER LeBARON PLYMOUTH CARAVELLE SALON AND GRAN FURY SALON DODGE
DIPLOMAT SALON AND DIPLOMAT S.E. CHRYSLER NEWPORT AND FIFTH AVENUE EAGLE
PREMIER DODGE ARIES AND PLYMOUTH RELIANT
CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT
ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS
CAREFULLY AND USE ONLY THE SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Call Out Description Quantity
A Instructions - Child Seat 1
Tether Anchorage Installation
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5391
B Spacer - Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
D Nut - Child Seat Tether 1
Anchorage
E Reinforcement - Child Seat 1
Tether Anchorage
F Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURE
1. Locate one of three holes in the shelf panel. (They can be seen by looking through the elliptical
slots in the shelf panel reinforcement from inside the trunk.)
2. Insert a sharp pencil through the hole and pierce the carpet covering the shelf panel.
3. Locate (from inside the rear passenger compartment) the access hole in the panel covered by
the carpet (this is the area around the pencil tip).
4. Using a sharp knife, remove 30 mm of carpeting around the pencil.
5. Only for: Eagle Premier
Enlarge the 9 mm access hole by cutting the gated tabs on the trim panel.
Only for: Plymouth Caravelle Salon and Gran Fury Salon Dodge Diplomat Salon and Diplomat S.E.
Chrysler Newport and Fifth Avenue
With a screw driver, enlarge the 9 mm access hole by separating the 32 mm perforated hole from
the shelf trim panel.
6. Insert the bolt through the plate, spacer, and shelf panel.
7. From the underside of the shelf panel, place the reinforcement on the bolt and hand tighten the
flanged nut.
8. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.)
While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
Pkg. No. 4519071
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5392
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5393
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE PLYMOUTH ACCLAIM AND DODGE SPIRIT
CHRYSLER NEW YORKER FIFTH AVE.
CHRYSLER IMPERIAL INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519071
CHILD SEAT TETHER ANCHORAGE
PLYMOUTH ACCLAIM AND DODGE SPIRIT CHRYSLER NEW YORKER FIFTH AVENUE
CHRYSLER IMPERIAL
CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT
ATTEMPT INSTALLATION IN
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5394
ANY OTHER VEHICLE. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE
ENCLOSED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
A Instruction - Child Seat 1
Tether Anchorage Installation
B Spacer - Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
D Nut - Child Seat Tether 1
Anchorage
E Reinforcement - Child Seat 1
Tether Anchorage
F Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURE
1. Open deck lid and remove luggage compartment front liner (if applicable).
2. Locate one of three 9 mm holes in shelf panel. (They can be seen by looking through the
elliptical slots in the shelf panel reinforcement from inside the trunk.)
3. Insert a sharp pencil through the 9 mm hole and pierce the carpet covering the shelf panel.
4. Locate (from inside the rear passenger compartment) the access hole in the panel covered by
the carpet (this is the area around the pencil tip).
5. Using a sharp knife, remove 30 mm of carpeting around the pencil.
6. Insert a screw driver through the 9 mm hole and remove the perforated 32 mm hole plug in the
shelf trim panel.
7. Insert the bolt through the plate, spacer, and shelf panel.
8. From the underside of the shelf panel, place the reinforcement on the bolt and hand tighten the
flanged nut.
9. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON).
While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
10. REPLACE THE LUGGAGE COMPARTMENT FRONT LINER (IF APPLICABLE).
Pkg. No. 4358469
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5395
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE
PLYMOUTH AND DODGE RAM WAGON INSTALLATION INSTRUCTIONS
PACKAGE NO. 4358469
CHILD SEAT TETHER ANCHORAGE PACKAGE
DODGE RAM WAGON
CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT
ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS
CAREFULLY AND USE ONLY THE ENCLOSED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5396
A Instructions - Child Seat 1
Anchorage
B Spacer - Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
D Nut - Child Seat Tether 1
Anchorage
E Reinforcement - Child Seat 1
Tether Anchorage Sealing Washer
F Plate - Child Seat Tether 1
Anchorage
G Template - Child Seat Tether 1
Anchorage Locating
INSTALLATION PROCEDURE
1. Remove the first rear seat (and the second rear seat if applicable) from the vehicle.
2. Place the template on the floor carpet.
3. Position the template over the rear attaching cups in the floor pan for the first rear passenger
seat.
4. Locate the center of one of the two anchor locations shown on the template and transfer this
location to the carpet.
5. Remove the template
6. Using a sharp knife, cut a one-inch cross cut in the carpet and carpet underlayment at the
transferred mark established in Step 4.
7. Locate the depression (dimple) in the floor pan, located beneath the cross cuts in the carpet.
8. Drill a 9 mm (3/8 inch) hole into the floor at the point marked by the depression.
9. Cut a 25.4 mm (1.00 inch) diameter hole in the carpet and underlayment around the hole in the
floor pan.
10. Insert the bolt through the plate, spacer, and floor.
11. From the underside of the vehicle, place the reinforcement on the bolt and hand tighten the
flanged nut (assure that the sealer side of the reinforcement is placed against the floor).
12. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.)
While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
Pkg. No. 4519072
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5397
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5398
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE
DODGE DYNASTY AND CHRYSLER NEW YORKER
AND CHRYSLER NEW YORKER LANDAU INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519072
CHILD SEAT TETHER ANCHORAGE
DODGE DYNASTY, CHRYSLER NEW YORKER AND CHRYSLER NEW YORKER LANDAU
CAUTION: THIS PACKAGE IS ONLY FOR THE OUTBOARD REAR SEATING POSITIONS OF
THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY
OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE
SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
A Instructions - Child Seat 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5399
Tether Anchorage Installation
B Spacer - Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
D Nut - Child Seat Tether 1
Anchorage
E Reinforcement - Child Seat 1
Tether Anchorage
F Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURES
1. Open deck lid and remove the luggage compartment front liner (if applicable).
2. Locate the three 9 mm bumps in the shelf panel. (They can be seen, from inside the trunk, at the
center of the circular formations in the shelf panel.)
3. (NOTE: USE ONE OF THE TWO OUTBOARD BUMPS.)
Insert a screwdriver at the bump and remove the 32 mm perforated hole plug in the shelf trim panel
foundation.
4. Insert a sharp pencil through the hole and pierce the carpet covering the shelf panel.
5. Locate (from inside the rear passenger compartment) the access hole in the panel covered by
the carpet (this is area around the pencil tip).
6. Using a sharp knife, remove the carpeting covering the hole.
7. Insert the bolt through the plate, spacer, and shelf panel.
8. From the underside of the shelf panel, place the reinforcement on the bolt and hand tighten the
flanged nut.
9. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.)
While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
10. Replace the luggage compartment front liner.
Pkg. No. 4519073
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5400
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5401
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE
DODGE DYNASTY AND CHRYSLER NEW YORKER
CHRYSLER NEW YORKER LANDAU INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519073
CHILD SEAT TETHER ANCHORAGE
DODGE DYNASTY AND CHRYSLER NEW YORKER CHRYSLER NEW YORKER LANDAU
CAUTION: THIS PACKAGE IS ONLY FOR THE REAR CENTER SEATING POSITION OF THE
1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY
OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE
SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
A Instructions - Child Seat 1
Tether Anchorage Installation
B Spacer - Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5402
D Nut Child Seat Tether 1
Anchorage
E Reinforcement - Child Seat 1
Tether Anchorage
F Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURES
1. Open deck lid and remove the luggage compartment front liner (if applicable).
2. Locate the three 9 mm bumps in the shelf panel. (They can be seen, from inside the trunk, at the
center of the circular formations in the shelf panel.)
3. (NOTE: USE ONLY THE CENTER LOCATION.)
Insert a screwdriver at the bump and remove the 32 mm perforated hole plug in the shelf trim panel
foundation.
4. Insert a sharp pencil through the hole and pierce the carpet covering the shelf panel.
5. Locate (from inside the rear passenger compartment) the access hole in the panel covered by
the carpet (this is area around the pencil tip).
6. Using a sharp knife, remove the carpeting covering the hole.
7. Insert the bolt through the plate, spacer, and shelf panel.
8. From the underside of the shelf panel, place the reinforcement on the bolt and hand tighten the
flanged nut.
9. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.)
While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
10. Replace the luggage compartment front liner (if applicable).
Pkg. No. 4519074
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5403
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5404
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE DODGE DAYTONA SHELBY Z AND DODGE DAYTONA
PACIFICA INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519074
CHILD SEAT TETHER ANCHORAGE PACKAGE
DODGE DAYTONA, DAYTONA SHELBY Z, AND DAYTONA PACIFICA
CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT
ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS
CAREFULLY AND USE ONLY THE SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5405
A Instructions - Child Seat 1
Tether Anchorage Installation
B Spacer - Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
D Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURES
1. Dodge Daytona (Plastic Trim Panel)
Open the hatch and locate the two plastic plugs in the hatch trim panel and remove one of the
plugs.
Dodge Daytona Shelby Z or a Dodge Daytona Pacifica
There are no plugs. The holes for the anchorage in the hatch opening lower trim panel will be
covered with carpet. Locate one of the two holes through the unsupported carpet. Using a sharp
knife, remove the carpet covering the hole.
2. Insert the bolt through the plate and spacer.
3. Hand start the bolt into the rear fascia attaching bracket located behind the trim panel.
4. While holding the plate as shown in the illustration, tighten the bolt (tighten nut to 250
inch-pounds torque).
Pkg. No. 4519075
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5406
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5407
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE DODGE LANCER AND LANCER ES AND CHRYSLER LE
BARON GTS INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519075
CHILD SEAT TETHER ANCHORAGE PACKAGE
DODGE LANCER AND LANCER ES AND CHRYSLER LeBARON GTS
CAUTION: THIS PACKAGE IS ONLY FOR THE REAR OUTBOARD SEATING POSITIONS FOR
THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY
OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE
SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
A Instructions - Child Seat 1
Tether Anchorage Installation
B Spacer - Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
D Nut - Child Seat Tether 1
Anchorage
E Reinforcement - Child Seat 1
Tether Anchorage Sealing Washer
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5408
F Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURES
1. Open the hatch and locate the three plastic caps (approximately 30 mm diameter) in the lower
trim panel.
2. (NOTE: USE ONE OF THE TWO OUTBOARD LOCATIONS.)
Remove the plastic cap.
3. Using a screw driver, push the steel plug out of the sheet metal panel (the plug can be seen
through the hole in the trim panel where the plastic cap was located).
4. Insert the bolt through the plate, spacer, and the hatch opening panel.
5. From the underside of the bumper, place the reinforcement on the bolt and hand tighten the
flanged nut (assure that the foam sealer is positioned next to the panel).
6. While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
Pkg. No. 4519076
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5409
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5410
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE
DODGE LANCER AND LANCER ES AND CHRYSLER LE BARON GTS INSTALLATION
INSTRUCTIONS
PACKAGE NO. 4519076
CHILD SEAT TETHER ANCHORAGE PACKAGE
DODGE LANCER AND LANCER ES AND CHRYSLER LeBARON GTS
CAUTION: THIS PACKAGE IS ONLY FOR THE REAR CENTER SEATING POSITION FOR THE
1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY
OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE
SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
A Instructions - Child Seat 1
Tether Anchorage Installation
B Spacer - Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
D Nut - Child Seat Tether 1
Anchorage
E Reinforcement - Child Seat 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5411
Tether Anchorage Sealing Washer
F Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURES
1. Open the hatch and locate the three plastic caps (approximately 30 mm diameter) in the lower
trim panel.
2. (NOTE: ONLY USE THE CENTER LOCATION FOR THIS APPLICATION).
Remove the plastic cap.
3. Using a screw driver, push the steel plug out of the sheet metal panel (the plug can be seen
through the hole in the trim panel where the plastic cap was removed).
4. Insert the bolt through the plate, spacer, and the hatch opening panel.
5. From the undersigned of the bumper, place the reinforcement on the bolt and hand tighten the
flanged nut (assure that the foam sealer is positioned next to the panel).
6. While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
Pkg. No. 4519080
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5412
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE
PLYMOUTH HORIZON AND DODGE OMNI INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519080
CHILD SEAT TETHER ANCHORAGE
PLYMOUTH HORIZON AND DODGE OMNI
CAUTION: THIS PACKAGE IS ONLY FOR THE REAR OUTBOARD SEATING LOCATIONS FOR
THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY
OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE
SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5413
A Instructions - Child Seat 1
Tether Anchorage Installation
B Bolt - Child Seat Tether 1
Anchorage
C Nut - Child Seat Tether 1
Anchorage
D Reinforcement - Child Seat 1
Tether Anchorage
E Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURES
1. Open cargo hatch.
2. Lift the floor carpet up, exposing the sheet metal.
3. Locate three steel plugs located on the floor.
4. Select one of the two outboard plugs and remove with a screwdriver.
NOTE: DO NOT USE THE CENTER LOCATION.
5. Insert the bolt through the plate and the floor.
6. From the underside of the vehicle, place the reinforcement on the bolt and hand tighten the
flanged nut (assure that the sealer side of the reinforcement is placed against the floor).
7. (NOTE: THIS OPERATION MAY REQUIRE THE ASSISTANCE OF ANOTHER PERSON.)
While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
8. Lower the carpet into its normal position and with a sharp knife cut a slot in the carpet over the
anchor to expose the plate end, as shown in the illustration.
9. Slip the carpet over the plate and press the outside edge of the carpet onto the velcro strip.
Pkg. No. 4519081
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5414
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE PLYMOUTH HORIZON AND DODGE OMNI
INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519081
CHILD SEAT TETHER ANCHORAGE
PLYMOUTH HORIZON AND DODGE OMNI - REAR CENTER
CAUTION: THIS PACKAGE IS ONLY FOR THE REAR CENTER SEATING LOCATION FOR THE
1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY
OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE
SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5415
A Instructions - Child Seat 1
Tether Anchorage Installation
B Bolt - Child Seat Tether 1
Anchorage
C Nut - Child Seat Tether 1
Anchorage
D Reinforcement - Child Seat 1
Tether Anchorage
E Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURES
1. Open cargo hatch.
2. Lift the floor carpet up exposing the sheet metal.
3. Locate three steel plugs located on the floor.
4. Remove the center plug with a screw driver. Do not use the outboard plugs.
5. Insert the bolt through the plate and the floor.
6. From the underside of the vehicle, place the reinforcement on the bolt and hand tighten the
flanged nut (assure that the sealer side of the reinforcement is placed against the floor).
7. (NOTE: THIS OPERATION MAY REQUIRE THE ASSISTANCE OF ANOTHER PERSON.)
While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
8. Lower the carpet into its normal position and with a sharp knife cut slot in the carpet over the
anchor to expose the plate end, as shown in the illustration.
9. Slip the carpet over the plate and press the outside edge of the carpet onto the velcro strip.
Pkg. No. 4519082
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5416
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE
PLYMOUTH VOYAGER AND GRAND VOYAGER
DODGE CARAVAN AND GRAND CARAVAN 7 PASSENGER
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5417
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE
PLYMOUTH VOYAGER AND GRAND VOYAGER
DODGE CARAVAN AND GRAND CARAVAN
5 PASSENGER INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519082
CHILD SEAT TETHER ANCHORAGE
PLYMOUTH VOYAGER AND GRAND VOYAGER DODGE CARAVAN AND GRAND CARAVAN
CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT
ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS
CAREFULLY AND USE ONLY THE SPECIFIED PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
A Instructions - Child Seat 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5418
Anchorage
B Spacer Child Seat Tether 1
Anchorage
C Bolt - Child Seat Tether 1
Anchorage
D Nut - Child Seat Tether 1
Anchorage
E Reinforcement - Child Seat 1
Tether Anchorage Sealing Washer
F Plate - Child Seat Tether 1
Anchorage
G Template - Child Seat Tether 1
Anchorage Locating
INSTALLATION PROCEDURE
1. 5 Passenger Vehicle
Remove the rear seat from the vehicle.
7 Passenger Vehicle.
Remove the second rear seat from the vehicle.
2. Place the template on the floor carpet.
3. 5 Passenger Vehicle
Position the template over the rear attaching cups in the floor pan with the passenger seat
removed.
7 Passenger Vehicle
Position the template over the front attaching cups in the floor pan with the passenger seat
removed.
4. Locate the center of one of the two anchor locations shown on the template and transfer this
location to the carpet.
5. Remove the template.
6. Using a sharp knife, cut a one-inch cross cut in the carpet and carpet underlayment at the
transferred mark established in Step 4.
7. Locate the depression (dimple) in the floor pan, located beneath the cross cuts in the carpet.
8. Drill a 9 mm (3/8 inch) hole into the floor at the point marked by the depression.
9. Cut a 25.4 mm (1.00 inch diameter hole in the carpet and underlayment around the hole in the
floor pan).
10. Insert the bolt through the plate, spacer, and floor.
11. From the underside of the vehicle, place the reinforcement on the bolt and hand tighten the
flanged nut (assure that the sealer side of the reinforcement is placed against the floor).
12. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.)
While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
Pkg. No. 4519292
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5419
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5420
INSTALLATION INSTRUCTIONS
CHILD SEAT TETHER ANCHORAGE DODGE SHADOW AND PLYMOUTH SUNDANCE
INSTALLATION INSTRUCTIONS
PACKAGE NO. 4519292
CHILD SEAT TETHER ANCHORAGE PACKAGE
DODGE SHADOW AND PLYMOUTH SUNDANCE
CAUTION: THIS PACKAGE IS ONLY FOR THE REAR SEATING POSITIONS FOR THE 1989
AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER
VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED
PARTS.
PACKAGE CONSISTS OF:
Cut Out Description Quantity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5421
A Instructions - Child Seat 1
Tether Anchorage Installation
B Bolt - Child Seat Tether 1
Anchorage
C Nut - Child Seat Tether 1
Anchorage
D Reinforcement - Child Seat 1
Tether Anchorage Sealing Washer
E Plate - Child Seat Tether 1
Anchorage
INSTALLATION PROCEDURES
1. Open the hatch and remove the screws securing the lower trim panel.
2. Remove the trim panel and locate three scored depression rings on the back of panel.
3. Remove the scored slug from the trim panel which is in line with the seating position used for the
child seat.
4. Using a sharp knife, remove the carpet covering the hole.
5. Using a screw driver, push the steel plug out of the sheet metal panel.
6. Replace the trim panel and the screws removed in Steps 1 and 2.
7. Insert the bolt through the plate and the hole in the hatch panel.
8. From the outside of the vehicle, place the reinforcement on the bolt and hand tighten the flanged
nut (assure that the foam sealer is positioned next to the sheet metal panel).
9. While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250
inch-pounds torque).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5422
Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts
Identification
NUMBER: 23-35-99 Rev. A
GROUP: Body
DATE: Oct. 1, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED
SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME
ALLOWANCES.
SUBJECT: Child Seat Tether Anchors
NOTE:
THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) LeBaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2000 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
1999 - 2000 (WJ) Grand Cherokee
1989 - 2000 (XJ) Cherokee/Wagoneer
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION
User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model
Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child
restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program,
owners of earlier products are expected to approach dealers for the free provision and installation
of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the
selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary
parts and a
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5423
detailed instruction sheet.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5424
PARTS REQUIRED:
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5425
POLICY: Customer Satisfaction
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5426
TIME ALLOWANCE:
Failure Code: CG - Customer Satisfaction
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Customer Interest: > 231491 > Nov > 91 > Seat Belt Anti-Rotation Tab - Modification
Seat Belt: Customer Interest Seat Belt Anti-Rotation Tab - Modification
NO.: 23-14-91
GROUP: BODY
DATE: Nov. 18, 1991
MODELS:
1984-1990 S-AS Caravan/Grand Caravan, Voyager/Grand Voyager/Town & Country
DISCUSSION:
On the listed models, when the first rear seat is removed from the vehicle and the second rear seat
is moved forward, it is possible for passengers to come in contact with the tip of the right outboard
seat belt assembly when entering the vehicle. To prevent contact with the outboard belt when
entering the vehicle, the belt assembly can be removed and the anti-rotation tab bent so the belt
assembly swings freely. This modification will allow the seat belt assembly to rotate toward the floor
allowing entry without contacting the tip of the belt.
CAUTION: OWNERS WHO HAVE THIS SERVICE PERFORMED ON THEIR VEHICLE SHOULD
BE ADVISED THAT THE MODIFIED SEAT BELT RETRACTOR ASSEMBLY MUST BE HELD
VERTICALLY WHEN INSTALLING THE SEAT IN THE SECOND REAR SEAT POSITION.
REPAIR PROCEDURE:
Figure 1
This procedure involves bending the anti-rotation tab in the right outboard seat belt assembly on
the rear seat.
1. Remove the right outboard seat belt assembly from the second rear seat assembly.
2. Bend the anti-rotation tab inward so the belt assembly will rotate freely (Figure 1).
3. Install the belt, tightening the retaining bolt to 350 in.lbs. (28 N-m) torque.
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 231491 > Nov > 91 > Seat Belt Anti-Rotation Tab Modification
Seat Belt: All Technical Service Bulletins Seat Belt Anti-Rotation Tab - Modification
NO.: 23-14-91
GROUP: BODY
DATE: Nov. 18, 1991
MODELS:
1984-1990 S-AS Caravan/Grand Caravan, Voyager/Grand Voyager/Town & Country
DISCUSSION:
On the listed models, when the first rear seat is removed from the vehicle and the second rear seat
is moved forward, it is possible for passengers to come in contact with the tip of the right outboard
seat belt assembly when entering the vehicle. To prevent contact with the outboard belt when
entering the vehicle, the belt assembly can be removed and the anti-rotation tab bent so the belt
assembly swings freely. This modification will allow the seat belt assembly to rotate toward the floor
allowing entry without contacting the tip of the belt.
CAUTION: OWNERS WHO HAVE THIS SERVICE PERFORMED ON THEIR VEHICLE SHOULD
BE ADVISED THAT THE MODIFIED SEAT BELT RETRACTOR ASSEMBLY MUST BE HELD
VERTICALLY WHEN INSTALLING THE SEAT IN THE SECOND REAR SEAT POSITION.
REPAIR PROCEDURE:
Figure 1
This procedure involves bending the anti-rotation tab in the right outboard seat belt assembly on
the rear seat.
1. Remove the right outboard seat belt assembly from the second rear seat assembly.
2. Bend the anti-rotation tab inward so the belt assembly will rotate freely (Figure 1).
3. Install the belt, tightening the retaining bolt to 350 in.lbs. (28 N-m) torque.
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 232189 > Aug > 89 > Rear Seat Shoulder Belt - Retrofit
Kits
Seat Belt: All Technical Service Bulletins Rear Seat Shoulder Belt - Retrofit Kits
Models
1984-1990 S/AS Bodies
Subject
Rear Seat Shoulder Belt Retrofit Kits
Index
BODY & SHEET METAL
Date August 21, 1989
No.
23-21-89
(C23-25-9)
P-3131 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/MINI RAM VAN/GRAND CARAVAN/GRAND
VOYAGER
THIS TECHNICAL SERVICE BULLETIN IS AN ADDENDUM TO TECHNICAL SERVICE
BULLETIN # 23-06-87 ISSUED ON MARCH 16, 1987.
PROCEDURE
In response to customer interest, rear seat shoulder belt retrofit kits have been developed and are
now available for the Caravan and Voyager vehicles. Upon customer request, the kits listed below
can be ordered and installed per the instructions enclosed in each kit. The customer is responsible
for all parts and labor expenses incurred.
Body Model Type Qty. Part No.
S/AS 1984-1990 All 1 4571683
112" Wheelbase 5-Passenger
S/AS 1984-1990 All 2 4571683
112" Wheelbase 7-Passenger
S/AS 1987-1990 All 1 4571687
119" Wheelbase 5-Passenger
S/AS 1987-1990 All 2 4571687
119" Wheelbase 7-Passenger
NOTE: EACH KIT CONTAINS THE PARTS, TEMPLATES AND INSTRUCTION SHEETS
REQUIRED TO INSTALL ONE LEFT SIDE AND ONE RIGHT SIDE REAR SEAT SHOULDER
BELT. THE 7-PASSENGER MODELS REQUIRE TWO (2) KITS AS SHOWN ABOVE.
POLICY: For information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Seat Belt: > 232189 > Aug > 89 > Rear Seat Shoulder Belt - Retrofit Kits
Seat Belt: All Technical Service Bulletins Rear Seat Shoulder Belt - Retrofit Kits
Models
1984-1990 S/AS Bodies
Subject
Rear Seat Shoulder Belt Retrofit Kits
Index
BODY & SHEET METAL
Date August 21, 1989
No.
23-21-89
(C23-25-9)
P-3131 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/MINI RAM VAN/GRAND CARAVAN/GRAND
VOYAGER
THIS TECHNICAL SERVICE BULLETIN IS AN ADDENDUM TO TECHNICAL SERVICE
BULLETIN # 23-06-87 ISSUED ON MARCH 16, 1987.
PROCEDURE
In response to customer interest, rear seat shoulder belt retrofit kits have been developed and are
now available for the Caravan and Voyager vehicles. Upon customer request, the kits listed below
can be ordered and installed per the instructions enclosed in each kit. The customer is responsible
for all parts and labor expenses incurred.
Body Model Type Qty. Part No.
S/AS 1984-1990 All 1 4571683
112" Wheelbase 5-Passenger
S/AS 1984-1990 All 2 4571683
112" Wheelbase 7-Passenger
S/AS 1987-1990 All 1 4571687
119" Wheelbase 5-Passenger
S/AS 1987-1990 All 2 4571687
119" Wheelbase 7-Passenger
NOTE: EACH KIT CONTAINS THE PARTS, TEMPLATES AND INSTRUCTION SHEETS
REQUIRED TO INSTALL ONE LEFT SIDE AND ONE RIGHT SIDE REAR SEAT SHOULDER
BELT. THE 7-PASSENGER MODELS REQUIRE TWO (2) KITS AS SHOWN ABOVE.
POLICY: For information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations
Technical Service Bulletin # 08-23-99 Date: 990709
Radio Communication Equipment - Recommendations
NUMBER: 08-23-99
GROUP: Electrical
DATE: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17,
1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000
MODEL YEAR VEHICLES.
SUBJECT: Installation of Radio Transmitting Equipment
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram
Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth
Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000**
(DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ)
Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New
Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ)
Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand
Cherokee/Grand Wagoneer
DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment
Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in
properly installing communication equipment in DaimlerChrysler vehicles. This information should
be given to any owner inquiring about installing radio-transmitting equipment.
Installation Recommendations
DaimlerChrysler
Radio Communication Equipment Installation Recommendations
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations > Page 5454
The following is excerpted from the owners manual of new DaimlerChrysler products:
"INSTALLATION OF RADIO TRANSMITTING EQUIPMENT
Special design considerations are incorporated into this vehicle's electronic system to provide
immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be
installed properly by trained personnel. The following must be observed during installation.
The positive power connection should be made directly to the battery and fused as close to the
battery as possible. The negative power connection should be made to body sheet metal adjacent
to the negative battery connection. This connection should not be fused.
Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care
should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or
operation of the compass on vehicles so equipped.
The antenna cable should be as short as practical and routed away from the vehicle wiring when
possible. Use only fully shielded coaxial cable.
Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR).
Mobile radio equipment with output power greater than normal may require special precautions.
All installations should be checked for possible interference between the communications
equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for
detailed assistance."
The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied
with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the
problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles,
the following information is provided. Always use good construction practices (see The ARRL
Handbook or other standard reference works).
The information contained in this guide has been prepared for use by persons installing two-way
radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with
current engineering principles and generally accepted practices, using the best information
available at the time of publication. It is not possible to cover all of the possible installations of
two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held
responsible for incidental or consequent damages arising out of the use of the information
contained herein. The responsibility for installations and modifications is the sole responsibility of
the customer.
The installation recommendations presented here are intended to supplement the radio
manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and
brake control before extensive driving.
1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan,
put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are
available at most body shops for this purpose.) This will keep moisture out of the carpet and
insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and
behind instrument panel.
If you mount the radio under the instrument panel, be sure that there is no interference with proper
operation of the foot controls. Mount the control head or front panel (especially the microphone
cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit
is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and
energy absorbing materials in the knee blocker (the lower part of the Instrument Panel).
For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power
relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed.
Try the installation out before you start drilling holes.
2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery
NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.:
radio presets) after a protracted time without battery power.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations > Page 5455
For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or
cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat
shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +)
lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle
has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder
and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard
corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and
the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola
Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG
cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi
Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with
cover 12033731 for standard SAE plastic fuses.
Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher
underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas.
Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest
location.
DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply
current would be conducted by an alternate current return path, which could cause the feedline to
overheat, with possible resulting damage.
For low or medium power installations, connect the ground (battery -) to body sheet near the power
feed point. If you use a screw through the floor, put body sealer over the underbody projection.
(Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high
power installations, connect the ground (battery -) lead at the battery connection to the body. This
is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse
or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so
diameter area of body panel where the ground lead is to be connected (usually the case with
commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or
5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size
for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the
terminal and the screw head. As above, some grease or protectant should be used if the
connection is in an unprotected area.
If the power cable must pass through the dash panel, try to find an existing hole with a grommet
that is unused. If none is available, pull the carpet back from under the dash panel in the passenger
footwell in the cabin. Locate a place where there are no other components on either side, as high
up as possible. An awl is the best tool to use to punch a small hole through to the engine
compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is
not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will
leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or
commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the
underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold,
steering shaft, throttle linkage, fans, etc. Tie wrap as required.
3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets
the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats
or carpet and padding. For most left hand drive vehicles, use the right side for best separation to
the main body harness (usually on the left side).
Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible.
4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to
remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is
usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the
front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear
compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping
points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which
must be pierced to pass the cable.
Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie
wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back
and cushion, taking care that the cable is not pinched by the seat cushion when there is someone
sitting in the seat. On some vehicles, there may be a channel for wiring at this location.
For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a
good method to mount the transceiver to the shelf. It provides a good mounting surface, some
shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of
the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be
mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic
modules located in the rear of the vehicle.
In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22
watts (@70% efficiency). Do not pile things on top of the unit.
5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way
as the control and power cables. Route flat along body sheet metal wherever possible to avoid
sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some
cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is
important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is
not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at
UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits.
Do not rely on the obsolete military "RG" designations as an indicator of quality.
Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the
correct connector.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations > Page 5456
The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A
small amount of silicone dielectric grease (not the white heat sink compound) in the connector
(after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize
losses.
6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile
installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the
center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas
should be mounted at the very top edge of the clear portion of the glass away from the heater grid.
Vehicles with printed-on-glass antennas may be damaged by through-glass installations.
For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are
an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel
for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for
corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A
small grinder with a coarse stone will break through the anodized coating for electrical connection.
7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass
or body-lip mounts for anything other than for low power or temporary installations. Most of these
alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from
the feedline inside the passenger compartment, and may be picked up by the vehicle wiring.
For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short,
wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and
even some FM installations, the hood must be bonded to the body. In some cases the doors may
need to be bonded, as well.
Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass
(Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper)
require a half-wavelength antenna or a ground plane with radius approximately equal to the length
of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used.
Install on the inside of the body panel with a good adhesive or tape and provide a good RF
connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used.
Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay
one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof
mechanism for interference to the base and to the feedline.
For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center
conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in
antenna selection and is the best choice for electrical and mechanical considerations. Use the
proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with
power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the
antenna base.
To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where
the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or
plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through,
leaving 6 in., which can be taped, to the transmission line (easier without the connector, but
possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the
hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps
maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small
amount of silicone grease to the contact and insulator surface of the base. This will help exclude
water, but must be renewed periodically. Tip: if you remove your antenna to go through the car
wash, there are caps available to exclude water during the process.
In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If
necessary, the technique used on the roof can also be used to snake the cable down the inside the
pillar.
Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a
clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are
a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely
important.
Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler
Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations
Technical Service Bulletin # 08-23-99 Date: 990709
Radio Communication Equipment - Recommendations
NUMBER: 08-23-99
GROUP: Electrical
DATE: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17,
1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000
MODEL YEAR VEHICLES.
SUBJECT: Installation of Radio Transmitting Equipment
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram
Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth
Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000**
(DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ)
Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New
Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ)
Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand
Cherokee/Grand Wagoneer
DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment
Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in
properly installing communication equipment in DaimlerChrysler vehicles. This information should
be given to any owner inquiring about installing radio-transmitting equipment.
Installation Recommendations
DaimlerChrysler
Radio Communication Equipment Installation Recommendations
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5461
The following is excerpted from the owners manual of new DaimlerChrysler products:
"INSTALLATION OF RADIO TRANSMITTING EQUIPMENT
Special design considerations are incorporated into this vehicle's electronic system to provide
immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be
installed properly by trained personnel. The following must be observed during installation.
The positive power connection should be made directly to the battery and fused as close to the
battery as possible. The negative power connection should be made to body sheet metal adjacent
to the negative battery connection. This connection should not be fused.
Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care
should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or
operation of the compass on vehicles so equipped.
The antenna cable should be as short as practical and routed away from the vehicle wiring when
possible. Use only fully shielded coaxial cable.
Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR).
Mobile radio equipment with output power greater than normal may require special precautions.
All installations should be checked for possible interference between the communications
equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for
detailed assistance."
The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied
with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the
problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles,
the following information is provided. Always use good construction practices (see The ARRL
Handbook or other standard reference works).
The information contained in this guide has been prepared for use by persons installing two-way
radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with
current engineering principles and generally accepted practices, using the best information
available at the time of publication. It is not possible to cover all of the possible installations of
two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held
responsible for incidental or consequent damages arising out of the use of the information
contained herein. The responsibility for installations and modifications is the sole responsibility of
the customer.
The installation recommendations presented here are intended to supplement the radio
manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and
brake control before extensive driving.
1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan,
put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are
available at most body shops for this purpose.) This will keep moisture out of the carpet and
insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and
behind instrument panel.
If you mount the radio under the instrument panel, be sure that there is no interference with proper
operation of the foot controls. Mount the control head or front panel (especially the microphone
cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit
is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and
energy absorbing materials in the knee blocker (the lower part of the Instrument Panel).
For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power
relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed.
Try the installation out before you start drilling holes.
2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery
NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.:
radio presets) after a protracted time without battery power.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5462
For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or
cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat
shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +)
lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle
has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder
and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard
corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and
the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola
Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG
cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi
Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with
cover 12033731 for standard SAE plastic fuses.
Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher
underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas.
Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest
location.
DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply
current would be conducted by an alternate current return path, which could cause the feedline to
overheat, with possible resulting damage.
For low or medium power installations, connect the ground (battery -) to body sheet near the power
feed point. If you use a screw through the floor, put body sealer over the underbody projection.
(Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high
power installations, connect the ground (battery -) lead at the battery connection to the body. This
is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse
or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so
diameter area of body panel where the ground lead is to be connected (usually the case with
commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or
5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size
for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the
terminal and the screw head. As above, some grease or protectant should be used if the
connection is in an unprotected area.
If the power cable must pass through the dash panel, try to find an existing hole with a grommet
that is unused. If none is available, pull the carpet back from under the dash panel in the passenger
footwell in the cabin. Locate a place where there are no other components on either side, as high
up as possible. An awl is the best tool to use to punch a small hole through to the engine
compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is
not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will
leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or
commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the
underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold,
steering shaft, throttle linkage, fans, etc. Tie wrap as required.
3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets
the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats
or carpet and padding. For most left hand drive vehicles, use the right side for best separation to
the main body harness (usually on the left side).
Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible.
4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to
remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is
usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the
front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear
compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping
points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which
must be pierced to pass the cable.
Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie
wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back
and cushion, taking care that the cable is not pinched by the seat cushion when there is someone
sitting in the seat. On some vehicles, there may be a channel for wiring at this location.
For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a
good method to mount the transceiver to the shelf. It provides a good mounting surface, some
shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of
the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be
mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic
modules located in the rear of the vehicle.
In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22
watts (@70% efficiency). Do not pile things on top of the unit.
5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way
as the control and power cables. Route flat along body sheet metal wherever possible to avoid
sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some
cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is
important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is
not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at
UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits.
Do not rely on the obsolete military "RG" designations as an indicator of quality.
Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the
correct connector.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5463
The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A
small amount of silicone dielectric grease (not the white heat sink compound) in the connector
(after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize
losses.
6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile
installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the
center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas
should be mounted at the very top edge of the clear portion of the glass away from the heater grid.
Vehicles with printed-on-glass antennas may be damaged by through-glass installations.
For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are
an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel
for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for
corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A
small grinder with a coarse stone will break through the anodized coating for electrical connection.
7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass
or body-lip mounts for anything other than for low power or temporary installations. Most of these
alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from
the feedline inside the passenger compartment, and may be picked up by the vehicle wiring.
For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short,
wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and
even some FM installations, the hood must be bonded to the body. In some cases the doors may
need to be bonded, as well.
Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass
(Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper)
require a half-wavelength antenna or a ground plane with radius approximately equal to the length
of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used.
Install on the inside of the body panel with a good adhesive or tape and provide a good RF
connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used.
Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay
one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof
mechanism for interference to the base and to the feedline.
For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center
conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in
antenna selection and is the best choice for electrical and mechanical considerations. Use the
proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with
power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the
antenna base.
To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where
the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or
plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through,
leaving 6 in., which can be taped, to the transmission line (easier without the connector, but
possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the
hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps
maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small
amount of silicone grease to the contact and insulator surface of the base. This will help exclude
water, but must be renewed periodically. Tip: if you remove your antenna to go through the car
wash, there are caps available to exclude water during the process.
In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If
necessary, the technique used on the roof can also be used to snake the cable down the inside the
pillar.
Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a
clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are
a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely
important.
Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler
Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions
Driver/Vehicle Information Display: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 5468
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 5469
Vehicle Information Center Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Diagrams > Diagram Information and Instructions
Radio/Stereo: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Diagrams > Diagram Information and Instructions > Page 5475
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Diagrams > Diagram Information and Instructions > Page 5476
Radio/Stereo: Electrical Diagrams
Radio Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Diagrams > Diagram Information and Instructions > Page 5477
Radio Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Diagrams > Page 5478
Radio/Stereo: Service and Repair
1. If equipped, remove forward console.
2. Disconnect battery ground cable.
3. Remove three attaching screws from top of bezel, then remove ashtray.
4. Remove two attaching screws at lower edge of bezel, then pull bezel rearward to release clip at
left side of bezel.
5. Remove two radio to instrument panel attaching screws, then pull radio through front face of
panel.
6. Disconnect radio electrical connector, antenna lead and ground strap.
7. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit >
Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions
Trailer Adapter Kit: Technical Service Bulletins Trailer Tow Wiring/Components - Installation
Cautions
NO.: 08-05-91
GROUP: ELECTRICAL
DATE: Apr. 22, 1991
SUBJECT: Trailer Tow Wiring Installation
MODELS:
ALL DODGE TRUCKS
DISCUSSION:
Improper installation of trailer tow wiring or electrical components can cause erratic operation of the
vehicles electrical system. When installing wiring or additional components, or diagnosing a vehicle
with erratic electrical operation, observe the following guidelines.
^ Inspect trailer wiring for bare or broken wires, corroded splices and terminals, shorted lamp
sockets, poor or insufficient grounding between the trailer wiring system and trailer frame.
^ When connecting lighting circuits, use a factory trailer tow wiring harness or a Mopar service kit if
available. Mopar kits include mating connectors and do not require cutting or splicing of vehicle
wiring. If cutting or splicing is required, the attached Wiring Procedure should be followed.
^ When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and
winches) make sure that the tow vehicles electrical ground is hard wired to the trailer electrical
ground. Ground wires should be attached to a clean, bare metal surface, not to a painted surface.
DO NOT rely on the trailer hitch coupling for ground.
^ When using butt splice connectors, test the splice integrity by pulling on the wires after crimping.
^ DO NOT use insulation displacement or insulation piercing crimp type terminals.
^ Some electrical equipment will require splicing into the vehicle wiring. Follow the attached Wiring
Procedure when installing these components.
WIRING PROCEDURE
1. With the ignition key in the OFF position, disconnect the battery.
2. Remove one inch of insulation from each wire to be connected.
3. Slide a piece of heat shrink tubing (PN 4419644) onto one wire.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit >
Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions > Page 5484
4. Spread the strands of each wire apart (Example 1).
5. Push the ends of the wire together until the strands are close to the insulation (Example 2).
6. Twist the wires together (Example 3).
7. Solder the twisted wire ends using a ROSIN CORE SOLDER.
8. Slide the piece of heat shrink tubing down to cover the splice. Be careful to center the tubing on
the splice. Using a heat gun, heat the tubing until it shrinks and seals the splice.
9. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Lighting Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 5489
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 5490
Trailer Lighting Module: Electrical Diagrams
Rear Lighting & Trailer Tow Wiring Circuit SH-68 - Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 5491
Rear Lighting & Trailer Tow Wiring Circuit SH-79 - Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions
Body Control Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 5498
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > Customer Interest: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine
Overheating
Front Bumper Cover / Fascia: Customer Interest Bumper Fascia - Causing Engine Overheating
Models
1988 S Body 1989-1990 AS Body
Subject
Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia
Index
COOLING
Date
January 29, 1990
No.
07-01-90
P-123 (C07-02-9) BODY CODE LEGEND
S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft
fascia may experience an overheating condition ( temperature gauge reads in the red zone) when
one or more of the following conditions is present.
1. Vehicle is fully loaded and/or pulling a trailer.
2. Vehicle is being operated in hilly or mountainous terrain.
3. Ambient temperatures are 90~F or above.
DIAGNOSIS
Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is
correct and no cooling system leaks are evident.
PARTS REQUIRED
Package - Air Dam and Front Fascia Template PN 5263408
Consists of: 1
Air Dam
7 Screws and Washers
1 Template
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > Customer Interest: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine
Overheating > Page 5509
Figure 1
REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the
installation of an air dam.
1. Raise vehicle on a hoist.
2. Position and temporarily affix the template to the bottom of the fascia with masking tape as
shown in Figure 1.
3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas
indicated on the template using a 1/8" (.125 inch) drill bit.
4. Remove the template.
5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen
(14) 2-1/2" holes through the bottom of the fascia.
6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator
crossmember.
7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding
toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the
existing holes in the lower radiator crossmember.
8. Starting at the center and working outward, tighten the seven screws.
9. Lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 9R - Engine runs hot
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 070190 > Jan
> 90 > Bumper Fascia - Causing Engine Overheating
Front Bumper Cover / Fascia: All Technical Service Bulletins Bumper Fascia - Causing Engine
Overheating
Models
1988 S Body 1989-1990 AS Body
Subject
Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia
Index
COOLING
Date
January 29, 1990
No.
07-01-90
P-123 (C07-02-9) BODY CODE LEGEND
S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft
fascia may experience an overheating condition ( temperature gauge reads in the red zone) when
one or more of the following conditions is present.
1. Vehicle is fully loaded and/or pulling a trailer.
2. Vehicle is being operated in hilly or mountainous terrain.
3. Ambient temperatures are 90~F or above.
DIAGNOSIS
Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is
correct and no cooling system leaks are evident.
PARTS REQUIRED
Package - Air Dam and Front Fascia Template PN 5263408
Consists of: 1
Air Dam
7 Screws and Washers
1 Template
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 070190 > Jan
> 90 > Bumper Fascia - Causing Engine Overheating > Page 5515
Figure 1
REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the
installation of an air dam.
1. Raise vehicle on a hoist.
2. Position and temporarily affix the template to the bottom of the fascia with masking tape as
shown in Figure 1.
3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas
indicated on the template using a 1/8" (.125 inch) drill bit.
4. Remove the template.
5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen
(14) 2-1/2" holes through the bottom of the fascia.
6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator
crossmember.
7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding
toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the
existing holes in the lower radiator crossmember.
8. Starting at the center and working outward, tighten the seven screws.
9. Lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 9R - Engine runs hot
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180694 > Apr >
94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13
Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In
Sag/DTC 13
NO: 18-06-94
GROUP: Vehicle Performance
DATE: Apr. 22, 1994
SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic)
MODELS:
1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC
TRANSAXLES.
SYMPTOM/CONDITION:
In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or
hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic).
DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic
procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order for future reference and repair as
necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are
functioning correctly, proceed with the following repair.
PARTS REQUIRED:
REPAIR PROCEDURE:
This repair involves the replacement of the Powertrain Control Module with a module that has
revised software.
1. With the ignition switch in the OFF position, disconnect the battery.
2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called
out in "PARTS REQUIRED".
3. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180694 > Apr >
94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 5521
4. Type the required information on the Authorized Modification Label (as illustrated), and attach
near the VECI Label.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-01-94 0.5 Hrs.
FAILURE CODE: NP - Sags, Hesitates
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180991 > Sep >
91 > Check Engine Lamp Comes On and Fault Code 13
Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and
Fault Code 13
NO.: 18-09-91
GROUP: DRIVEABILITY
DATE: Sept. 23, 1991
SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine
MODELS:
1989 (AA) SPIRIT/ACCLAIM
1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON
1989 (AG) DAYTONA
1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE
1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER
SYMPTOM/CONDITION:
The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic
Change" is set into the diagnostic system.
DIAGNOSIS:
Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP
Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor
vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the
diagnostic manual to verify that the MAP sensor is operating properly.
PARTS REQUIRED:
1 MAP Sensor Relocation Package 4638458
Package Contents: 1
Cap Plug (1987-88 vehicles) 3580172
1 Cap Plug (1989 vehicles) 4241618
1 Purge Jumper Assembly 4669038
Consisting of: 1
In-Line Vacuum Connector 4201275
1 Vacuum Tee 33000227
1 11" Vacuum Hose 4104272
1 Bleed/Hose Assembly 4669042
Consisting of:
1 Vent 53007494
1 1" Vacuum Hose 4713956
1 Vacuum Tee 4669041
2 Vacuum Hose With 90 Degree Bend 4669044
1 Bracket 4686013
1 Wiring Harness 4687141
5 Tie Wraps 6015756
REPAIR PROCEDURE:
This repair involves relocation of the MAP sensor.
1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable.
2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its
present location.
3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug
(3580172 for 1987 and 1988 vehicles or 4241618
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180991 > Sep >
91 > Check Engine Lamp Comes On and Fault Code 13 > Page 5526
for 1989 vehicles) in its place.
4. Loosen clamps and remove throttle body/air filter intake hose.
5. Wiring Harness Installation Procedure:
If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted
on the right side shock tower or on the bulkhead follow Step B.
A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor
connector. Route the harness along the backside of
the intake manifold toward the throttle body. The harness should be secured to the fuel line and to
the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps.
B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length.
Connect the FEMALE end of the harness to
the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the
harness to the right side of the motor mount and the two rear engine wiring support brackets.
Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the
harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the
supplied tie wraps.
6. Attach original MAP sensor to the bracket (4686013) supplied in the package.
Figure 1
7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to
slide over throttle body stud.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180991 > Sep >
91 > Check Engine Lamp Comes On and Fault Code 13 > Page 5527
Figure 2
8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque
nut to 25 N-m (225 in.lbs.).
9. Disconnect the intake manifold end of the formed purge hose that extends from the intake
manifold nipple to the "F" shaped connector (Figure 2).
Figure 3
10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to
nipple on intake manifold. Position the MAP bleed valve
as close to vertical as possible.
Figure 4
11. Cut the existing PVC hose as shown in Figure 2.
12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the
formed purge hose (disconnected in Step 9) and the PVC
hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed
purge hose.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180991 > Sep >
91 > Check Engine Lamp Comes On and Fault Code 13 > Page 5528
Figure 5
NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER
ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE
IT OVER THE TOP OF THROTTLE LINKAGE.
13. Connect vacuum hose to MAP sensor.
14. Connect wiring harness connector to MAP sensor.
15. Install throttle body/air filter intake hose and tighten clamps.
16. Use the DRB II to erase any fault codes and perform the applicable verification tests.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 08-14-15-94
. . . . . . . . . . . . . . . . . 0.8 Hrs.
FAILURE CODE: 58 - Internal Defect
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180390 > Jan >
90 > MAP Sensor - DTC's 13 or 14 Set
Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set
Models
1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies
Subject
MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines
Index
DRIVEABILITY
Date
January 29, 1990
No.
18-03-90
(C18-20-9)
P-164 BODY
CODE LEGEND
AA - ACCLAIM/,SPIRIT LEBARON LANDAU
C/AC - DYNASTY/NEW YORKER LANDAU/SALON
E - CARAVELLE/600
G/AG - DAYTONA
H/AH - LANCER/LEBARON GTS
J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE
K/AK - ARIES/RELIANT
P/AP - SHADOW/SUNDANCE
S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic
Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle
diagnostic memory.
PARTS REQUIRED
1 MAP Sensor PN 5227351
1 Sensor Hose (3.0L Engine Only) PN 4557138
REPAIR PROCEDURE
When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement
part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP
sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service
Manual for replacement procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 091689 > Oct >
89 > Engine - Oil Consumption
Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 091689 > Oct >
89 > Engine - Oil Consumption > Page 5537
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 5538
Front Bumper Cover / Fascia: By Symptom
Technical Service Bulletin # 070190 Date: 900129
Bumper Fascia - Causing Engine Overheating
Models
1988 S Body 1989-1990 AS Body
Subject
Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia
Index
COOLING
Date
January 29, 1990
No.
07-01-90
P-123 (C07-02-9) BODY CODE LEGEND
S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft
fascia may experience an overheating condition ( temperature gauge reads in the red zone) when
one or more of the following conditions is present.
1. Vehicle is fully loaded and/or pulling a trailer.
2. Vehicle is being operated in hilly or mountainous terrain.
3. Ambient temperatures are 90~F or above.
DIAGNOSIS
Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is
correct and no cooling system leaks are evident.
PARTS REQUIRED
Package - Air Dam and Front Fascia Template PN 5263408
Consists of: 1
Air Dam
7 Screws and Washers
1 Template
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 5539
Figure 1
REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the
installation of an air dam.
1. Raise vehicle on a hoist.
2. Position and temporarily affix the template to the bottom of the fascia with masking tape as
shown in Figure 1.
3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas
indicated on the template using a 1/8" (.125 inch) drill bit.
4. Remove the template.
5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen
(14) 2-1/2" holes through the bottom of the fascia.
6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator
crossmember.
7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding
toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the
existing holes in the lower radiator crossmember.
8. Starting at the center and working outward, tighten the seven screws.
9. Lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 9R - Engine runs hot
Technical Service Bulletin # 070190 Date: 900129
Bumper Fascia - Causing Engine Overheating
Models
1988 S Body 1989-1990 AS Body
Subject
Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 5540
Index
COOLING
Date
January 29, 1990
No.
07-01-90
P-123 (C07-02-9) BODY CODE LEGEND
S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft
fascia may experience an overheating condition ( temperature gauge reads in the red zone) when
one or more of the following conditions is present.
1. Vehicle is fully loaded and/or pulling a trailer.
2. Vehicle is being operated in hilly or mountainous terrain.
3. Ambient temperatures are 90~F or above.
DIAGNOSIS
Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is
correct and no cooling system leaks are evident.
PARTS REQUIRED
Package - Air Dam and Front Fascia Template PN 5263408
Consists of: 1
Air Dam
7 Screws and Washers
1 Template
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 5541
Figure 1
REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the
installation of an air dam.
1. Raise vehicle on a hoist.
2. Position and temporarily affix the template to the bottom of the fascia with masking tape as
shown in Figure 1.
3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas
indicated on the template using a 1/8" (.125 inch) drill bit.
4. Remove the template.
5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen
(14) 2-1/2" holes through the bottom of the fascia.
6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator
crossmember.
7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding
toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the
existing holes in the lower radiator crossmember.
8. Starting at the center and working outward, tighten the seven screws.
9. Lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 9R - Engine runs hot
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
System Information > Service and Repair > Interior Door Handle
Front Door Handle: Service and Repair Interior Door Handle
Front Door Trim Panel
1. Remove trim panel and liner. 2. Raise glass with switch or window crank.
Latch Assembly, Striker, And Linkage
3. Unclip links at the door latch. 4. Remove links from anti-rattle clips.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
System Information > Service and Repair > Interior Door Handle > Page 5549
Front Door Assembly
5. Remove remote control assembly by removing three screws and pulling links out of the door. 6.
Remove links from the remote handle as required to replace handle or link. 7. Reverse removal
procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
System Information > Service and Repair > Interior Door Handle > Page 5550
Front Door Handle: Service and Repair Exterior Door Handle
Front Door Trim Panel
1. Remove door trim panel. 2. Remove liner to clear rear of major access hole and door. 3. Roll
glass up.
Latch Assembly, Striker, And Linkage
4. Disconnect outside handle and lock cylinder links at the latch. 5. Remove the lock cylinder link.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
System Information > Service and Repair > Interior Door Handle > Page 5551
Outside Handle/Lock Cylinder
6. Remove two attaching nuts, outside handle and reinforcing plate. 7. Reverse procedure to
install. Adjust latch prior to trim panel installation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair
Front Door Latch: Service and Repair
Front Door Trim Panel
1. Remove trim panel and liner. 2. Raise window to full-up position.
Latch Assembly, Striker, And Linkage
3. Disconnect all links at latch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Page 5555
Front Door Assembly
4. Remove three torx screws from the door inside panel. 5. Remove latch assembly. 6. To
assemble reverse removal procedure. Adjust outside handle at the latch as soon as all links are
secured.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair
Front Door Panel: Service and Repair
REMOVAL
Front Door Trim Panel
1. Lower the door glass until it is 3 inches (75 mm) from the full-down position.
2. Remove the remote handle bezel with the door unlocked by prying the front of the bezel out and
rearward.
3. Remove the screw in the armrest pocket.
4. Pry out the door lock switch bezel.
5. Remove the window crank (if equipped with manual windows).
6. Remove the door trim panel, (retained with frog legged clips) and push the power lock switch
through the door trim panel.
7. Disconnect the courtesy light pigtail.
8. Remove plastic and foam composite door liner where access is required.
INSTALLATION
1. Apply adhesive to the door liner and fasten it to the inner door panel.
2. Connect the courtesy light pigtail.
3. Push the power lock switch through the door trim panel and install the door trim panel.
4. Push the power lock switch into place.
5. Attach the window crank (if equipped with manual windows).
6. Install the screw through the armrest pocket.
7. Install the remote handle bezel with the door unlocked by pushing the bezel in and forward.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip >
Component Information > Service and Repair
Front Door Weatherstrip: Service and Repair
Front Door Trim Panel
1. Remove trim panel. 2. Remove five outer belt weatherstrip screws, and remove weatherstrip,
using an offset screwdriver. 3. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass
> System Information > Service and Repair
Front Door Window Glass: Service and Repair
Glass To Regulator
REMOVAL
1. Remove trim panel and door liner. See: Front Door Panel/Service and Repair
2. Raise the door glass until the two (2) nuts align with access holes in the inner door panel.
3. Remove the two (2) glass plate nuts that hold the door glass to the front window regulator
assembly.
4. Remove the glass through the belt opening, using the notch at the rear of the door to clear the
glass fasteners (pull the glass towards the inside of the vehicle when removing).
INSTALLATION
1. Slide the door glass into the door through the belt opening, using the notch at the rear of the
door to clear the glass fasteners.
2. Install the two (2) glass plate nuts that hold the door glass to the front window regulator
assembly and tighten finger tight.
3. To adjust the door glass, raise glass to full up position and secure glass attaching nuts.
3. Install the door liner and door trim panel. See: Front Door Panel/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor
> Component Information > Service and Repair
Front Door Window Motor: Service and Repair
Power Window Regulator Assembly
REMOVAL
1. Remove trim panel and door liner. See: Front Door Panel/Service and Repair
2. Remove the front door glass. See: Front Door Window Glass/Service and Repair
3. Remove the power window regulator assembly. See: Windows and Glass/Windows/Window
Regulator/Service and Repair/Power Window Regulator Replacement
4. Drill out the two (2) rivets mounting the power window lift motor to the window regulator.
5. Remove the power window lift motor off of the regulator.
INSTALLATION
1. Position the power window lift motor onto the power window regulator and install two (2) 1/4-20
X 1/2 screws in place of the rivets that were drilled out for removal. Torque the mounting screws to
90 lb-ft (11 Nm).
2. Install the power window regulator assembly. See: Windows and Glass/Windows/Window
Regulator/Service and Repair/Power Window Regulator Replacement
3. Install the front door glass. See: Front Door Window Glass/Service and Repair
4. Install the door liner and door trim panel. See: Front Door Panel/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Adjustments
Sliding Door Handle: Adjustments
Four areas of the latch remote locking control can be adjusted: the lock knob, inside handle,
outside handle, and the front hook. These components should be adjusted when they fail to
operate properly.
Latch Remote Locking Control
To simplify service of the sliding door latches and locks, a latch remote locking control is used. This
assembly consolidates the door locks and latch remote control mechanisms into one unit. It can be
accessed for removal and replacement by removing the door trim panel.
Adjusting The Lock Knob
Perform the lock knob adjustment with the door open. Loosen the lowermost allen head screw on
the control assembly. Then lock the latch by pulling the locking link forward and tighten the allen
head screw to 25 in. lbs. (3 Nm).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Adjustments > Page 5572
Adjusting The Inside Handle
Adjust the inside handle setting by loosening the uppermost allen head screw on the left side of the
assembly. Insert a screwdriver through the square hole in the assembly and pull the latch link
upward far enough to remove any free play. Then tighten the allen head screw to 25 in. lbs. (3 Nm).
Adjusting The Outside Handle
The outside handle can be adjusted by loosening the lowermost allen head screw of the central
pivot. Then hold the central pivot cam against the outside handle actuator button and tighten the all
en head screw to 25 in lbs. (3 Nm).
Adjusting The Front Hook
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Adjustments > Page 5573
The front hook adjustment must be performed with the door closed. Begin this adjustment by
loosening the uppermost allen head screw at the central pivot. Push the front hook actuator link
forward until it bottoms on the hook and tighten the allen head screw to 25 in. lbs. (3 Nm).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Adjustments > Page 5574
Sliding Door Handle: Service and Repair
Sliding Door Trim Panel
1. Remove trim panel.
Latch Remote Locking Control
2. Remove 8 control assembly to door bolts. 3. Disconnect linkage and wiring harness. 4. Remove
control assembly. 5. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim
Panel > Component Information > Service and Repair
Sliding Door Interior Trim Panel: Service and Repair
*** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-08-88 DATED MAY 16, 1988
REMOVAL
Sliding Door Trim Panel
1. With door closed, remove door latch remote control bezel.
2. Remove two (2) plugs and screws holding upper arm cover to the trim panel.
3. Remove seven (7) plastic trim panel fasteners.
4. Remove one (1) plug and screw from the trim panel.
5. On carpet trim panel models, remove the hidden screw from the upper rearward corner of the
carpet insert.
6. Disengage five (5) frogleg fasteners used to retain the trim panel to the door.
7. Remove the christmas tree fastener from the center of the carpet insert (if applicable).
7. Remove the trim panel.
INSTALLATION
1. Raise the trim panel to the door and push the five (5) frogleg fasteners, and the one (1)
christmas fastener (if applicable), into the door.
2. Install one (1) screw and plug through the trim panel into the door.
3. On carpet trim panel models, install the hidden screw into the upper rearward corner of the
carpet insert.
3. Install the seven (7) plastic trim panel fasteners.
4. Install the two (2) screws and plugs used to fasten the upper arm trim cover to the door.
5. Install the door latch remote control bezel.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch >
System Information > Service and Repair
Sliding Door Latch: Service and Repair
1. Remove trim panel. 2. Open door and remove linkage from connectors at the latch. 3. After
removing three latch retaining screws, remove the latch. 4. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Cable >
Component Information > Service and Repair
Fuel Door Release Cable: Service and Repair
REMOVAL
1. Raise vehicle on hoist. 2. Remove the four nuts that fasten the driver's seat riser to the floor pan.
3. Lower the hoist.
Fuel Door Remote Cable
4. Tilt the seat backwards, reach under the front of the seat and grab the cable close to the clip that
retains it to the lever assembly. 5. Pull the cable towards the drivers door until it is released from
the lever assembly. 6. Turn the cable 90° and push inward to separate the cable end from the lever
assembly. 7. Remove the driver's seat and riser assembly.
Rear Seat Removal (5 Passenger)
8. Remove the rear seat(s) by lifting the release lever on the front of both seat riser assemblies.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Cable >
Component Information > Service and Repair > Page 5585
9. Remove the left windshield side garnish moulding.
10. Remove the left front door scuff plate. 11. Remove the left "B" pillar garnish moulding and seat
belt. 12. Remove the liftgate scuff plate.
Garnish Mouldings And Trim Panels, Left Side
13. Remove the lower quarter trim panel.
Fuel Door Remote Cable
14. Lift carpet at the liftgate opening and remove the emergency release cable from the spare tire
winch actuating bolt and from the retaining clip. 15. Remove the fuel door remote cable retaining
nut that is located inside of the fuel door opening. 16. Remove the cable assembly, 17. Reverse
this procedure to install the cable. Observe and use all torque specifications as shown on the
illustrations.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
Power Trunk / Liftgate Lock Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > Recalls: > 95I001004 > Mar > 95 > Recall 95I001004: Liftgate Latch
Defect
Trunk / Liftgate Latch: Recalls Recall 95I001004: Liftgate Latch Defect
Light duty passenger minivans without remote release. This is not a safety recall. There has been
no determination that a safety defect exists with the minivan latches. Chrysler is conducting a
service campaign to replace the liftgate latch assembly of the affected minivans. In a collision, the
rear liftgate latch assembly could open.
If the liftgate latch opens, occupants can be ejected resulting in significantly increased risk of injury
or death.
Chrysler dealers will replace the liftgate latch with a new stronger latch assembly without charge.
Chrysler began notifying owners during November 1995.
This is not a safety recall. There has been no determination that a safety defect exists with the
minivan latches. However, Chrysler has decided to provide a stronger latch without charge.
Owners can contact Chrysler at 1-800-MINIVAN (1-800-646-4826).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > Recalls: > 95I001008 > Mar > 95 > Recall 95I001008: Liftgate Latch
Defect
Trunk / Liftgate Latch: Recalls Recall 95I001008: Liftgate Latch Defect
Light duty passenger minivans with remote release. This is not a safety recall. There has been no
determination that a safety defect exists with the minivan latches. Chrysler is conducting a service
campaign to replace the liftgate latch assembly of the affected minivans. In a collision, the rear
liftgate latch assembly could open.
If the liftgate latch opens, occupants can be ejected resulting in significantly increased risk of injury
or death. Chrysler dealers will replace the liftgate latch with a new stronger latch assembly without
charge.
Chrysler began notifying owners of these vehicles during July 1996.
This is not a safety recall. There has been no determination that a safety defect exists with the
minivan latches. However, Chrysler has decided to provide a stronger latch without charge.
Owners can contact Chrysler at 1-800-MINIVAN (1-800-646-4826).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95I001004 > Mar > 95 > Recall
95I001004: Liftgate Latch Defect
Trunk / Liftgate Latch: All Technical Service Bulletins Recall 95I001004: Liftgate Latch Defect
Light duty passenger minivans without remote release. This is not a safety recall. There has been
no determination that a safety defect exists with the minivan latches. Chrysler is conducting a
service campaign to replace the liftgate latch assembly of the affected minivans. In a collision, the
rear liftgate latch assembly could open.
If the liftgate latch opens, occupants can be ejected resulting in significantly increased risk of injury
or death.
Chrysler dealers will replace the liftgate latch with a new stronger latch assembly without charge.
Chrysler began notifying owners during November 1995.
This is not a safety recall. There has been no determination that a safety defect exists with the
minivan latches. However, Chrysler has decided to provide a stronger latch without charge.
Owners can contact Chrysler at 1-800-MINIVAN (1-800-646-4826).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95I001008 > Mar > 95 > Recall
95I001008: Liftgate Latch Defect
Trunk / Liftgate Latch: All Technical Service Bulletins Recall 95I001008: Liftgate Latch Defect
Light duty passenger minivans with remote release. This is not a safety recall. There has been no
determination that a safety defect exists with the minivan latches. Chrysler is conducting a service
campaign to replace the liftgate latch assembly of the affected minivans. In a collision, the rear
liftgate latch assembly could open.
If the liftgate latch opens, occupants can be ejected resulting in significantly increased risk of injury
or death. Chrysler dealers will replace the liftgate latch with a new stronger latch assembly without
charge.
Chrysler began notifying owners of these vehicles during July 1996.
This is not a safety recall. There has been no determination that a safety defect exists with the
minivan latches. However, Chrysler has decided to provide a stronger latch without charge.
Owners can contact Chrysler at 1-800-MINIVAN (1-800-646-4826).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 091689 > Oct
> 89 > Engine - Oil Consumption
Positive Crankcase Ventilation Valve: All Technical Service Bulletins Engine - Oil Consumption
Models
1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine
Subject
Abnormal Oil Consumption
Index
ENGINE
Date
October 16, 1989
No.
09-16-89
(C09-15-9)
P-3753 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM
C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN
& COUNTRY SYMPTOM/CONDITION
Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on
1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of
power, rough idle, hesitation and driveway dieout.
This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover
baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into
the PCV system.
Figure 1
DIAGNOSIS
Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil
is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge
accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain
hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and
the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate
Technical Service Manual.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 091689 > Oct
> 89 > Engine - Oil Consumption > Page 5616
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 091689 > Oct
> 89 > Engine - Oil Consumption > Page 5622
Figure 2
PARTS REQUIRED
1 Rocker Cover P/N MD156425
1 PCV Valve P/N MD102195
1 Gasket, Rocker Cover P/N MD133671
1 Silicone Rubber Adhesive (RTV) P/N 4318025
REPAIR PROCEDURE
This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP
sensor hose.
1. Remove the left rocker cover (FRONT).
2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425.
3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2.
4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10
N-m) torque.
5. Install new PCV valve P/N MD102195 in the rocker cover.
6. Clean the MAP sensor hose and PCV hose with compressed air.
7. Install the MAP sensor hose and PCV hose.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs.
FAILURE CODE: 70 - Oil Consumption
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Locations
Trunk / Liftgate Solenoid: Locations
Liftgate Components
Bottom Center Of Liftgate
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Locations
Trunk / Liftgate Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > Customer Interest for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH
Cross-Member: Customer Interest Exhaust System - Drone At 40-55 MPH
Models
1987-90 S/AS Bodies With 2.5L & 3.0L Engines
Subject
Exhaust Drone At 40-55 MPH
Index
EXHAUST
Date
September 18, 1989
No.
11-02-89
(C11-01-9)
P-3455 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH).
DIAGNOSIS
Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from
under the floor pan area in front of the first bench seat. The vibration will also be present if the
engine is run through the 2350-2450 RPM range with the transmission in neutral.
PARTS REQUIRED
1 Crossmember Assembly PN 4427322
1 Muffler Support Bracket PN 4427295
1 Heat Shield PN 4401855
4 Screw & Washer Assembly PN 6501305
4 U-Nut PN 6101283
REPAIR PROCEDURE
1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the
exhaust insulators to remain on the muffler.
2. Remove the muffler support bracket, crossmember, and heat shield.
3. Install new heat shield, using the fasteners just removed.
4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250
+/- 50 in. lbs., washer should bottom out on sleeve.
5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN
6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs.
6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the
bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs.
7. Road test vehicle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > Customer Interest for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH > Page
5638
TIME ALLOWANCE: Labor Operation No.
11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55
MPH
Cross-Member: All Technical Service Bulletins Exhaust System - Drone At 40-55 MPH
Models
1987-90 S/AS Bodies With 2.5L & 3.0L Engines
Subject
Exhaust Drone At 40-55 MPH
Index
EXHAUST
Date
September 18, 1989
No.
11-02-89
(C11-01-9)
P-3455 BODY CODE LEGEND
S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY
SYMPTOM/CONDITION
Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH).
DIAGNOSIS
Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from
under the floor pan area in front of the first bench seat. The vibration will also be present if the
engine is run through the 2350-2450 RPM range with the transmission in neutral.
PARTS REQUIRED
1 Crossmember Assembly PN 4427322
1 Muffler Support Bracket PN 4427295
1 Heat Shield PN 4401855
4 Screw & Washer Assembly PN 6501305
4 U-Nut PN 6101283
REPAIR PROCEDURE
1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the
exhaust insulators to remain on the muffler.
2. Remove the muffler support bracket, crossmember, and heat shield.
3. Install new heat shield, using the fasteners just removed.
4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250
+/- 50 in. lbs., washer should bottom out on sleeve.
5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN
6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs.
6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the
bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs.
7. Road test vehicle to verify the condition has been corrected.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55
MPH > Page 5644
TIME ALLOWANCE: Labor Operation No.
11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 68 - Noisy
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service
Bulletins > Trailer Tow Wiring/Components - Installation Cautions
Trailer Adapter Kit: Technical Service Bulletins Trailer Tow Wiring/Components - Installation
Cautions
NO.: 08-05-91
GROUP: ELECTRICAL
DATE: Apr. 22, 1991
SUBJECT: Trailer Tow Wiring Installation
MODELS:
ALL DODGE TRUCKS
DISCUSSION:
Improper installation of trailer tow wiring or electrical components can cause erratic operation of the
vehicles electrical system. When installing wiring or additional components, or diagnosing a vehicle
with erratic electrical operation, observe the following guidelines.
^ Inspect trailer wiring for bare or broken wires, corroded splices and terminals, shorted lamp
sockets, poor or insufficient grounding between the trailer wiring system and trailer frame.
^ When connecting lighting circuits, use a factory trailer tow wiring harness or a Mopar service kit if
available. Mopar kits include mating connectors and do not require cutting or splicing of vehicle
wiring. If cutting or splicing is required, the attached Wiring Procedure should be followed.
^ When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and
winches) make sure that the tow vehicles electrical ground is hard wired to the trailer electrical
ground. Ground wires should be attached to a clean, bare metal surface, not to a painted surface.
DO NOT rely on the trailer hitch coupling for ground.
^ When using butt splice connectors, test the splice integrity by pulling on the wires after crimping.
^ DO NOT use insulation displacement or insulation piercing crimp type terminals.
^ Some electrical equipment will require splicing into the vehicle wiring. Follow the attached Wiring
Procedure when installing these components.
WIRING PROCEDURE
1. With the ignition key in the OFF position, disconnect the battery.
2. Remove one inch of insulation from each wire to be connected.
3. Slide a piece of heat shrink tubing (PN 4419644) onto one wire.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service
Bulletins > Trailer Tow Wiring/Components - Installation Cautions > Page 5649
4. Spread the strands of each wire apart (Example 1).
5. Push the ends of the wire together until the strands are close to the insulation (Example 2).
6. Twist the wires together (Example 3).
7. Solder the twisted wire ends using a ROSIN CORE SOLDER.
8. Slide the piece of heat shrink tubing down to cover the splice. Be careful to center the tubing on
the splice. Using a heat gun, heat the tubing until it shrinks and seals the splice.
9. Connect the battery.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions
Console: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 5655
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 5656
Console: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 5657
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 5658
Overhead Console Lamps Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 5659
Overhead Console Lamps Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Page 5660
Console: Service and Repair
EXTENDED CONSOLE
Mounting Brackets
1. Install forward and rear mounting brackets with four screws. 2. Attach rear console, first making
sure headliner is between housing and upper plastic.
Mounting Console Assembly
3. Slide console rearwards until console stops. 4. Attach vent switch wire harness to vent switch
carrier. 5. Attach main wiring harness into compass module.
Connecting Harness
6. Press console to headliner, centering console between visor tip pin retainers. 7. While pressing
console upwards, slide console forward to attach console on front mounting tang.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Page 5661
Installing Console Assembly
8. Press upwards until consoles snap onto mounting bracket.
SHORT CONSOLE
1. Install forward and rear mounting brackets with four screws. 2. Attach vent switch wire harness
to vent switch carrier. 3. Press console to headliner, centering console between visor tip pin
retainers. 4. While pressing console upwards, slide console forward to attach console on front
mounting tang. 5. Press upwards until console snaps onto mounting brackets.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag System Arming and Disarming
1. Place ignition switch in lock position.
2. Disconnect and tape battery ground cable connector.
3. Wait at least 1 minute after disconnecting battery ground cable before performing any further
repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a
short time even after battery has been disconnected.
4. After repairs are performed, connect battery ground cable.
5. From passenger side of vehicle, turn ignition switch to On position.
6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to
indicate if SRS system is functioning correctly.
7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
and Repair
Headliner: Service and Repair
Headliner
1. Remove rear vent remote control handle covers. 2. Unscrew and remove both remote control
handles. 3. Disconnect battery negative cable and remove reading lamp, dome lamp, and cargo
lamps. 4. Remove the sun visors and sun visor clips. 5. Remove the windshield side garnish
mouldings. 6. Remove the first rear seat. 7. Remove front door scuff plates, side door scuff plate,
and liftgate scuff plate. 8. Remove "B" pillar garnish mouldings and seat belts. 9. Remove upper
track cover.
10. Remove lower quarter trim panel from left side. 11. Remove upper quarter trim panel from left
side. 12. Remove right quarter trim panel. 13. Remove headliner fasteners, and then headliner. 14.
Reverse this procedure for installation.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair
Trim Panel: Service and Repair
Interior Panels (Extended Wheelbase)
GENERAL INFORMATION
Because of the longer wheelbase made available in some of these vehicles, trim panels and
interior garnish mouldings have been extended or modified to meet the specifications of this
vehicle.
INTERIOR TRIM PANELS AND GARNISH MOULDINGS
Excellent fit and appearance are two benefits of overlapping garnish and trim panels on the interior
of the vehicle. With the exception of the windshield side garnish mouldings, sliding side door scuff
plate, and the liftgate scuff plate, a series of trim components must be removed in order to service
any other trim panel or garnish moulding. The following list is the sequence of removal that has
been found to be most effective.
Right Side 1. Right windshield side garnish moulding. 2. Right front door scuff plate. 3. Right "B"
pillar garnish moulding and seat belt. 4. Sliding side door upper track cover. 5. Sliding side door
scuff plate. 6. Liftgate scuff plate. 7. Right quarter trim panel. 8. Reverse the order of trim
components to install.
Left Side 1. Left windshield side garnish moulding. 2. Left front door scuff plate. 3. Left "B" pillar
garnish moulding and seat belt. 4. Liftgate scuff plate. 5. Lower quarter trim panel. 6. Upper quarter
trim panel. 7. Reverse the order of trim components to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Front Doors
Door Lock Cylinder: Service and Repair Front Doors
Outside Handle/Lock Cylinder
1. Remove outside handle. 2. Remove two screws, retainer and lock cylinder. 3. Reverse
procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Front Doors > Page 5678
Door Lock Cylinder: Service and Repair Sliding Side Door
Sliding Door Trim Panel
1. Remove trim panel.
Latch Remote Locking Control
2. Remove latch remote locking control assembly. 3. Remove 2 retainer nuts from inside of the
door and then pull the handle assembly from the outside of the door. 4. Remove 2 screws, and
separate lock cylinder from outside handle assembly. 5. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Front Door
Power Door Lock Actuator: Locations Front Door
Front Door Assembly
The power door lock motor is located in the bottom rear corner of the door, just below the door
latch assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Front Door > Page 5684
Power Door Lock Actuator: Locations Sliding Side Door
Sliding Side Door Power Lock Assembly
The power door lock motor, for the sliding door, is located behind the door lock contact plate at the
front of the door.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Locations > Page 5685
Power Door Lock Actuator: Testing and Inspection
Power Door Lock Motor
NOTE: Perform CIRCUIT BREAKER TEST prior to this test, and verify that the battery is fully
charged.
1. Check each door for lock and unlock or disconnect the motor connections one at a time while
operating the door lock switch.
2. If none of the door lock motors work, the problem may be caused by a shorted motor.
Disconnecting the defective motor will allow the others to work. NOTE: If one of the motors has a
broken pigtail connector, it should have no effect on the operation of the other door lock motors.
3. To test an individual lock motor, disconnect the lock motor electrical connector and do the
following: ^
Connect a 12 volt power source to the Orange wire terminal of the lock motor electrical connector
and ground the Pink wire terminal, this should lock the door.
^ Reverse the wires from the previous step (12 volts to the Pink wire and ground the Orange wire)
and the door should unlock.
^ If both results do not occur, check for a broken wire between the electrical connector and the lock
motor. If there are no broken wires, replace the lock motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Service and Repair > Front Door
Power Door Lock Actuator: Service and Repair Front Door
Front Door Assembly
REMOVAL
1. Remove door trim panel and liner. See: Doors, Hood and Trunk/Doors/Front Door/Front Door
Panel/Service and Repair
2. Raise door glass with service power window switch or crank.
3. Disconnect the power door lock electrical connector.
4. Drill out the two (2) lock motor mounting rivets.
5. Disconnect the lock motor link at the motor and remove the motor through the access hole.
INSTALLATION
1. Connect the lock motor to the linkage rod.
2. Attach the lock motor to its mounting bracket with two (2) 1/4-20 X 1/2 inch screws and nuts.
Torque to 90 lb-in (11 Nm).
3. Connect the lock motor electrical connector.
4. Install liner and trim panel. See: Doors, Hood and Trunk/Doors/Front Door/Front Door
Panel/Service and Repair
NOTE: If the rubber boot on the power door lock motor is twisted, the movement of the motor will
be restricted.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Service and Repair > Front Door > Page 5688
Power Door Lock Actuator: Service and Repair Sliding Door
REMOVAL
Sliding Door Power Lock Components
1. Remove door trim panel. See: Doors, Hood and Trunk/Doors/Sliding Door/Sliding Door Interior
Trim Panel/Service and Repair
2. Remove eight (8) control assembly to door mounting bolts.
3. Disconnect the lock linkage and the wiring harness.
4. Pull the control assembly out of the sliding door.
5. Disconnect the lock linkage from the lock motor and remove the lock motor from the control
assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Service and Repair > Front Door > Page 5689
INSTALLATION
1. Mount the lock motor to the control assembly and connect its lock linkage.
2. Connect the wiring harness and the lock linkage to the sliding door.
3. Install the control assembly into the sliding door.
4. Install and tighten the eight (8) control assembly mounting bolts.
5. Install the door trim panel. See: Doors, Hood and Trunk/Doors/Sliding Door/Sliding Door Interior
Trim Panel/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Locations
Power Door Lock Switch: Locations
Front Door Components
In Front Door Armrest
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Testing and Inspection > Sliding Door Circuit Test
Power Door Lock Switch: Testing and Inspection Sliding Door Circuit Test
Sliding Side Door Power Lock Assembly
1. Connect one lead of a test light to the upper contact of the pillar, and place the other lead to the
lower contact.
2. If the test light illuminates when the lock switch is depressed, the wiring circuit to the contacts is
good. If the test light does not illuminate, check the electrical connectors at the right side cowl,
check for a broken wire, or see Circuit Breaker Test.
3. With the sliding door partially open, connect jumper wires across contacts on pillar to contacts on
the door. The door should lock or unlock when
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Testing and Inspection > Sliding Door Circuit Test > Page 5695
these jumper wires are connected and the switch is depressed.
4. If the door locks and unlocks, the problem is in the door and pillar contacts (check for proper
shim at the door contact plate). If lock and unlock does not occur, remove trim panel and check for
voltage at the lock motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Testing and Inspection > Sliding Door Circuit Test > Page 5696
Power Door Lock Switch: Testing and Inspection Switch Voltage Test
NOTE: The following test determines whether voltage is continuous through the wiring harness to
the power door lock switch.
1. Remove the door lock switch from the door trim panel.
2. Separate the multiple terminal block on the wiring harness from the door lock switch.
3. Connect one lead of a test light to the black wire terminal and the other lead to the red wire
terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning
properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check
for an open in the wiring harness.
4. If the wiring circuit is functioning properly, See: Power Door Lock Actuator/Testing and
Inspection
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Testing and Inspection > Sliding Door Circuit Test > Page 5697
Power Door Lock Switch: Testing and Inspection Door Lock Switch Test
Door Lock Switch Continuity
Remove each door lock switch from the door trim panel. Connect an ohmmeter to the switch and
check that there is continuity in lock and unlock positions (refer to the image shown). If these
results are not obtained, replace the switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Testing and Inspection > Page 5698
Power Door Lock Switch: Service and Repair
1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect
wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
Power Mirror Switch: Locations
Front Door Components
In Center Of Door Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program
Paint: Technical Service Bulletins Paint - Variance Program
SUBJECT: Color Variance Program
NO.: 23-02-91
GROUP: BODY
DATE: Feb. 11, 1991
MODELS:
1984 - 1991 All Domestic Models
DISCUSSION:
The color variance charts from BASF, Sherwin-Williams, Martin Senour, Acme and Rogers are
being sent for use in solving off-color paint problems. The variance charts provide an alternate
color that will help the painter achieve a good match or a closer match than the factory pack.
Other manufacturers have paint variance programs available that are in a format not suitable for
mailing with a bulletin. Check with your local jobber.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5708
Technical Service Bulletin # 230889 Date: 890410
Paint - Codes/Applications/Cross References
Models
1989 Domestic & Import Passenger Cars & Trucks
Subject
1989 Standard Paint Colors
Index
BODY & SHEET METAL
Date
April 10, 1989
No.
23-08-89
P-1364 (C23-53)
The 1989 paint information is being provided for Chrysler, Plymouth, Dodge, Jeep, Eagle and
import models in one bulletin.
Paint codes are located on the vehicle information plate on each vehicle. THIS BULLETIN DOES
NOT LIST SALES CODES. The vehicle information plate locations are as follows:
CHRYSLER-PLYMOUTH-DODGE
Body Vehicle Code Plate Location
AC Left radiator yoke support/closure panel
AL Left radiator yoke support/closure panel
AP Left radiator yoke support/closure panel
AK Left radiator yoke support/closure panel
AG Center radiator yoke/closure panel
AH Left radiator yoke/closure panel
AM Middle of left inner fender shield above tire
AE Left radiator yoke/closure panel
AJ Center radiator yoke/closure panel
AS Right cowl/dash panel (under hood)
AN On floor pan under jack (Quick reference label under hood)
AD Right plenum - (View through cowl grill) (Quick reference label under hood)
AD/AW Right plenum - (View through cowl grill) (Quick reference label under hood)
AB Behind battery on cowl/dash panel (Quick
reference under hood)
Definitions of the body letter codes can be found on the model chart in the appropriate technical
service manual. JEEP-EAGLE
Body Vehicle Code Plate Location
YJ Left side of dash panel in the engine compartment
XJ Left radiator support in the engine compartment
MJ Left radiator support in the engine compartment
SJ Left side of the dash panel in the engine compartment
BB Right front strut tower in the engine compartment
BC Right front strut tower in the engine compartment
B2 Right center cowl/dash panel (under hood)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5709
CHRYSLER-PLYMOUTH-DODGE IMPORTS
Body Vehicle Code Plate Location
AQ (Maserati) Under hood near the left rear corner
B1 (Colt) Right center cowl/dash panel (under hood)
B3 (Vista) Left front inner fender shield
B4 (RAM 50) Right center cowl dash panel
B5 (Conquest) Center cowl/dash panel
B6 (Raider) Right center cowl/dash panel
The listed paint manufacturers have service representatives who are trained in the latest refinishing
methods and painting techniques. They can assist body shop personnel when necessary.
Color chip charts are available from the respective manufacturers through the local jobbers or
representatives.
NOTE: THIS INFORMATION SHOULD BE DIRECTED TO THE BODY SHOP FOREMAN
AND/OR BODY REPAIR PERSONNEL.
POLICY: For information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5710
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5711
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5712
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5713
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5714
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5715
Paint: Technical Service Bulletins Stone Guard - Paint Repair
NO.: 23-37-93
GROUP: Body
DATE: Jun. 25, 1993
SUBJECT: Anti-Chip (Stone Guard) Paint Repair
MODELS:
DISCUSSION:
To compete and stay in the forefront of paint technology, Chrysler Corporation introduced a stone
guard protector material in the 1980's. The stone guard material is applied to varied exterior
surfaces on all passenger cars and light trucks. These surfaces can include: Hoods, lower fenders,
rocker panels, lower doors, and lower quarter panels.
The following recommended repair procedures are provided by Chrysler paint suppliers, "BASF"
and "PPG". Other stone guard repair systems are available. Specific questions should be directed
to your local paint distributors.
"BASF" STONE GUARD REPAIR PROCEDURES
1. Wash the entire vehicle with water and a mild detergent soap, rinse thoroughly and let dry.
2. Clean the entire vehicle with R-M 909 Pre-Kleano for California and R-M 900 where the R-M 909
is not available or use Gasurit 541-5.
3. Using a "DA" sander, sand the damaged areas using 80 grit, or finer, to featheredge the
damage. Follow with 120 grit and final sanding with 240 grit.
NOTE 1: EXTEND THE FEATHEREDGE 1-1/2 TO 2 INCHES OUT. THIS WILL PREVENT A
BULLS EYE FROM APPEARING WHEN THE JOB IS DONE.
4. Mix either an epoxy primer or self-etch primer (DE 15 or DE 17).
5. Apply 1-2 light coats over the bare metal areas.
6. Allow the material to dry for 15 to 20 minutes before applying the stone ship protector.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Paint - Variance Program > Page 5716
7. Apply the Stone Chip Protector Glassohyd 1109-12406 over the prepared areas.
NOTE 2: GUN TECHNIQUE IS ESSENTIAL. BY CONTROLLING THE SPRAY-GUN OVER THE
PREPARED AREA, THE PAINTER CAN FEATHER THE STONE CHIP PROTECTOR AS IT IS
BEING SPRAYED. THE WETTER YOU APPLY THE MATERIAL, THE SMOOTHER IT WILL
FLOW OUT.
8. Allow the stone chip material to dry. Heat may be used to accelerate the dry times.
9. After the Stone Chip Protector has been applied, it may be top coated with a single or base-clear
urethane system.
"PPG" STONE GUARD REPAIR PROCEDURE
1. DX330 (Acryli-Clean Wax and Grease Remover).
2. Perform necessary repair*.
3. Re-clean with DX330.
4. DP (Epoxy Primer)**.
5. K-36 (Prima Primer-Surfacer).
6. DBU (Deltron Basecoat).
7. Apply Acrylic Urethane Clear.
*Ensure substrate is properly abraded to maintain optimum product performance.
** Apply if bare metal is exposed.
NOTE: ADHERE TO SPECIFIC PRODUCT BULLETINS FOR MIXING RATIOS AND PROPER
FLASH TIMES.
POLICY: Information only.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
Front Body Components
Front Center Of Headliner
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations
Power Seat Motor: Locations
Power Seat Components
On Bottom Of Seat
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations
Power Seat Switch: Locations
Power Seat Components
Outboard Side Of Seat
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations
Seat Heater Switch: Locations
Lower I/P Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair
Seat Track: Service and Repair
SEAT ADJUSTER, LEFT SIDE Removal
1. Remove the seat riser covers. 2. Remove the four nuts that fasten the adjuster assembly to the
seat risers. 3. Remove the adjuster covers. 4. Remove the four bolts that fasten the adjuster
assembly to the seat.
Installation
1. Hold the seat and adjuster together and install four bolts. Torque the bolts to 23 Nm (200 In.
Lbs.). 2. Install the adjuster covers and torque the screws to 3 Nm (24 In. Lbs.). 3. Place the seat
and adjuster assembly on the seat riser, install the four nuts, and torque the nuts to 23 Nm (200 In.
Lbs.). 4. Install the seat riser covers.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations
Power Door Lock Switch: Locations
Front Door Components
In Front Door Armrest
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Sliding Door Circuit Test
Power Door Lock Switch: Testing and Inspection Sliding Door Circuit Test
Sliding Side Door Power Lock Assembly
1. Connect one lead of a test light to the upper contact of the pillar, and place the other lead to the
lower contact.
2. If the test light illuminates when the lock switch is depressed, the wiring circuit to the contacts is
good. If the test light does not illuminate, check the electrical connectors at the right side cowl,
check for a broken wire, or see Circuit Breaker Test.
3. With the sliding door partially open, connect jumper wires across contacts on pillar to contacts on
the door. The door should lock or unlock when
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5741
these jumper wires are connected and the switch is depressed.
4. If the door locks and unlocks, the problem is in the door and pillar contacts (check for proper
shim at the door contact plate). If lock and unlock does not occur, remove trim panel and check for
voltage at the lock motor.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5742
Power Door Lock Switch: Testing and Inspection Switch Voltage Test
NOTE: The following test determines whether voltage is continuous through the wiring harness to
the power door lock switch.
1. Remove the door lock switch from the door trim panel.
2. Separate the multiple terminal block on the wiring harness from the door lock switch.
3. Connect one lead of a test light to the black wire terminal and the other lead to the red wire
terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning
properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check
for an open in the wiring harness.
4. If the wiring circuit is functioning properly, See: Locks/Power Locks/Power Door Lock
Actuator/Testing and Inspection
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5743
Power Door Lock Switch: Testing and Inspection Door Lock Switch Test
Door Lock Switch Continuity
Remove each door lock switch from the door trim panel. Connect an ohmmeter to the switch and
check that there is continuity in lock and unlock positions (refer to the image shown). If these
results are not obtained, replace the switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Page 5744
Power Door Lock Switch: Service and Repair
1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect
wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Power Mirror Switch: Locations
Front Door Components
In Center Of Door Panel
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations
Power Seat Switch: Locations
Power Seat Components
Outboard Side Of Seat
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
Power Trunk / Liftgate Lock Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations
Seat Heater Switch: Locations
Lower I/P Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations
Sunroof / Moonroof Switch: Locations
Front Body Components
Front Center Of Headliner
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations
Trunk / Liftgate Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair
Spare Tire Carrier: Service and Repair
REMOVAL
1. Open liftgate, lower and remove the spare tire from the winch assembly. 2. Raise vehicle on a
hoist.
Deflector Assembly
3. Remove the deflector assembly.
Spare Tire Support Assembly
4. Remove the spare tire support assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair > Page
5766
Winch Assembly
5. Remove the spare tire winch assembly.
INSTALLATION
1. Install spare tire winch assembly and torque the bolts to 28 Nm (250 In. Lbs.).
Spare Tire Support Assembly
2. Install spare tire support assembly and torque the bolts closest to the winch to 28 Nm (250 In.
Lbs.). Torque the two remaining bolts to 4 Nm (35
In. Lbs.).
3. Install the deflector assembly and torque the bolts closest to the winch to 28 Nm (250 In. Lbs.).
Torque the two remaining bolts to 4 Nm (35 In.
Lbs.).
4. Install the spare tire on winch and hoist it to proper position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information >
Technical Service Bulletins > Customer Interest for Air Dam: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine
Overheating
Air Dam: Customer Interest Bumper Fascia - Causing Engine Overheating
Models
1988 S Body 1989-1990 AS Body
Subject
Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia
Index
COOLING
Date
January 29, 1990
No.
07-01-90
P-123 (C07-02-9) BODY CODE LEGEND
S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft
fascia may experience an overheating condition ( temperature gauge reads in the red zone) when
one or more of the following conditions is present.
1. Vehicle is fully loaded and/or pulling a trailer.
2. Vehicle is being operated in hilly or mountainous terrain.
3. Ambient temperatures are 90~F or above.
DIAGNOSIS
Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is
correct and no cooling system leaks are evident.
PARTS REQUIRED
Package - Air Dam and Front Fascia Template PN 5263408
Consists of: 1
Air Dam
7 Screws and Washers
1 Template
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information >
Technical Service Bulletins > Customer Interest for Air Dam: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine
Overheating > Page 5776
Figure 1
REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the
installation of an air dam.
1. Raise vehicle on a hoist.
2. Position and temporarily affix the template to the bottom of the fascia with masking tape as
shown in Figure 1.
3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas
indicated on the template using a 1/8" (.125 inch) drill bit.
4. Remove the template.
5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen
(14) 2-1/2" holes through the bottom of the fascia.
6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator
crossmember.
7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding
toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the
existing holes in the lower radiator crossmember.
8. Starting at the center and working outward, tighten the seven screws.
9. Lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 9R - Engine runs hot
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Dam: > 070190 > Jan > 90 > Bumper Fascia - Causing
Engine Overheating
Air Dam: All Technical Service Bulletins Bumper Fascia - Causing Engine Overheating
Models
1988 S Body 1989-1990 AS Body
Subject
Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia
Index
COOLING
Date
January 29, 1990
No.
07-01-90
P-123 (C07-02-9) BODY CODE LEGEND
S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN &
COUNTRY
SYMPTOM/CONDITION
1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft
fascia may experience an overheating condition ( temperature gauge reads in the red zone) when
one or more of the following conditions is present.
1. Vehicle is fully loaded and/or pulling a trailer.
2. Vehicle is being operated in hilly or mountainous terrain.
3. Ambient temperatures are 90~F or above.
DIAGNOSIS
Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is
correct and no cooling system leaks are evident.
PARTS REQUIRED
Package - Air Dam and Front Fascia Template PN 5263408
Consists of: 1
Air Dam
7 Screws and Washers
1 Template
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Dam: > 070190 > Jan > 90 > Bumper Fascia - Causing
Engine Overheating > Page 5782
Figure 1
REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the
installation of an air dam.
1. Raise vehicle on a hoist.
2. Position and temporarily affix the template to the bottom of the fascia with masking tape as
shown in Figure 1.
3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas
indicated on the template using a 1/8" (.125 inch) drill bit.
4. Remove the template.
5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen
(14) 2-1/2" holes through the bottom of the fascia.
6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator
crossmember.
7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding
toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the
existing holes in the lower radiator crossmember.
8. Starting at the center and working outward, tighten the seven screws.
9. Lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs.
FAILURE CODE: 9R - Engine runs hot
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Front Shock Tower - Metal Screws/Bolts Precautions
Strut / Shock Tower: Technical Service Bulletins Front Shock Tower - Metal Screws/Bolts
Precautions
NO.: 02-08-92 GROUP: Suspension DATE: Dec. 14, 1992
SUBJECT: Installation Of Sheet Metal Screws Or Bolts Into The Front Shock Towers
MODELS:
1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 (AH) Lanced LeBaron GTS
1989 - 1993 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1990 (AQ) Horizon/Omni
1989 - 1993 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1991 (AQ) Chrysler's TC (Maserati Coupe)
1989 - 1993 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 (C) Dynasty/New Yorker
1984 - 1988 (E) Caravelle/600/New Yorker Turbo
1984 - 1988 (G) Daytona/Laser
1985 - 1988 (H) Lancer/LeBaron GTS
1987 - 1988 (J) LeBaron Coupe/LeBaron Convertible
1984 - 1988 (K) Reliant/Aries/LeBaron 4-Door/Town & Country
1984 - 1988 (L) Horizon/Omni
1987 - 1988 (P) Shadow/Sundance
1984 - 1988 (S) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country
DISCUSSION:
It is very important that no sheet metal screws, bolts or other metal fasteners be installed in the
shock towers in place of plastic clips. Also, no holes should be drilled in the shock tower for
installation of any metal fasteners (see illustration, area "A").
Because of the minimum clearance in this area, installation of metal fasteners could damage the
coil spring coating. If a plastic clip is lost or broken, replace the clip with the equivalent part called
out in the appropriate Mopar Parts Catalog.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Front Shock Tower - Metal Screws/Bolts Precautions > Page 5787
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair
Front Door Weatherstrip: Service and Repair
Front Door Trim Panel
1. Remove trim panel. 2. Remove five outer belt weatherstrip screws, and remove weatherstrip,
using an offset screwdriver. 3. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and
Inspection
Brake Switch (Cruise Control): Testing and Inspection
1. Disconnect six cavity connector from stop lamp switch pigtail. 2. Using an ohmmeter, check
continuity at switch side of connector. 3. With brake pedal released, there should be continuity
between the dark blue/red and yellow/red wires, and between white/pink and white wires.
There should be no continuity between pink and white wires.
4. With brake pedal depressed, there should be continuity between pink and white wires. There
should be no continuity between the dark blue/red
and yellow/red wires, or between white/pink and white wires.
5. If the above results are not obtained the stop lamp switch is defective or out of adjustment.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations
Clutch Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Clutch Pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations
Lower Instrument Panel Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 5802
Cruise Control Module: Testing and Inspection
Fig. 5 Engine Controller 60-Way Connector, Shown From Terminal End
1. Set voltmeter to read 12 volts, then connect negative lead to chassis ground. 2. Connect positive
lead to pin 7 of module connector then drive vehicle at speeds between 40 - 50 mph. 3. Turn speed
control switch to the On position. Voltmeter should read 12 volts. 4. Press and release the speed
control Set button. The voltmeter should indicate from 5 - 9 volts and fluctuate 1 - 2 volts at a rapid
rate. 5. Speed control system should be performing throttle control at this time, maintaining set
speed. If not, replace control module.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations
Engine Compartment Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 5806
Cruise Control Servo: Description and Operation
The speed control servo is a diaphragm and cable assembly. It is electrically actuated and vacuum
operated.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 5807
Cruise Control Servo: Testing and Inspection
Fig. 72 Servo Harness Connector
1. Turn ignition switch and speed control switch to the On position. 2. Set voltmeter to read battery
voltage. Connect negative lead to chassis ground. 3. Disconnect the 4-way connector to the servo.
Pin 2 should read approximately battery voltage. If not, check for loose connections or repair main
harness as necessary.
4. Connect a jumper wire between pin 2 of the 4-way connector and pin 2 of the speed control
servo. The other three male terminals from the servo
should show battery voltage.
5. Using an ohmmeter, connect one lead to ground, then touch the other lead to pin 1 of the 4-way
connector of the main harness. The meter should
indicate continuity. If not, repair ground circuit.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 5808
Cruise Control Servo: Service and Repair
REMOVAL
1. Remove two nuts attaching throttle cable and mounting bracket to servo. 2. Remove two screws
attaching servo mounting bracket to U-nuts on battery tray. 3. Remove servo mounting bracket. 4.
Disconnect electrical connector and vacuum hose. 5. Pull cable away from servo to expose
retaining clip and remove clip attaching cable to servo.
INSTALLATION
1. With throttle in full open position align hole in throttle cable sleeve with hole in servo pin and
install retaining clip. 2. Connect vacuum hose to reservoir. 3. Connect electrical connector. 4.
Position mounting bracket, install two screws attaching bracket to battery tray and tighten to 105 in.
lbs. (12 N-m). 5. Insert servo studs through holes in throttle cable and mounting bracket. 6. Install
nuts and tighten to 80 in lbs. (9 N-m).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair
Cruise Control Servo Cable: Service and Repair
Fig. 6 Speed Control Cable Adjustment
1. Remove air cleaner assembly. 2. On carbureted models, disconnect cable from carburetor stud
by removing spring clip. 3. Disconnect cable from throttle body by removing retaining clip. 4.
Disconnect cable from servo, then remove cable assembly. 5. Locate cable through servo
mounting bracket. 6. Connect cable sleeve to servo stud, align holes, then install clip. 7. Insert
servo studs through holes in cable and holes in bracket, then install nut-washers. 8. Route cable
from servo, through cable support bracket and clip, then install cable end on stud of throttle body.
9. On carbureted models, adjust control cable as follows:
a. Start engine and let run, until normal operating temperature is reached. b. Remove retaining clip.
c. Adjust clip until 1/16 inch clearance is achieved between throttle stud and cable clevis.
10. Replace air cleaner.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations
Cruise Control Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Brake pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5815
Cruise Control Switch: Testing and Inspection
Fig. 6 Speed Control Continuity Chart. 1988-90 Rear Wheel Drive Models
Fig. 7 Speed Control Continuity Chart. 1988-90 Front Wheel Drive Models
Fig. 8 Speed Control Connector Terminal Identification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5816
Fig. 9 Speed Control Continuity Chart. 1991 Models
1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a
continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. 3.
Results should be obtained according to the charts. If these results are not obtained, replace
switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5817
Cruise Control Switch: Service and Repair
1. Disconnect battery ground cable. 2. Remove lower steering column cover. 3. Remove four
plastic retaining clips from underside of steering column, then the trough. 4. Disconnect speed
control switch electrical connector from instrument panel harness connector. 5. Remove wiper
control knob from end of turn signal lever, then the silencer from lever. 6. Remove two screws
attaching speed control switch to column. 7. On tilt columns, remove steering wheel, then attach a
flexible guide wire to lower end of speed control switch harness. 8. Remove switch and harness
from column by gently pulling wires through lock housing between lock plate and side of housing.
9. On standard columns, remove attaching screws and the upper steering lock housing cover, then
pull harness up through column.
10. On tilt columns, insert harness connector through turn signal lever opening in column, then pull
upward through upper housing.
11. Attach guide wire to switch wiring harness, then gently pull downward through column opening,
between lock plate and side of housing.
12. On standard columns, insert harness and connector through turn signal lever opening in
column, then pull down and out lower end.
13. On all models, remove slack from all wires.
14. On tilt column, remove guide wires.
15. On all models, install wiring trough with plastic clips.
16. Connect speed control switch electrical connector to instrument panel harness connector.
17. Secure speed control switch to column with two screws.
18. Position silencer on lever, then push wiper control knob in place on end of lever.
19.
On tilt columns, replace steering wheel.
20. On standard columns, install upper steering column lock housing cover.
21. On all models, install lower steering column cover.
22. Connect battery ground cable, then test operation of speed control.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component
Information > Locations
Lower Instrument Panel Components
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component
Information > Locations > Page 5822
Cruise Control Module: Testing and Inspection
Fig. 5 Engine Controller 60-Way Connector, Shown From Terminal End
1. Set voltmeter to read 12 volts, then connect negative lead to chassis ground. 2. Connect positive
lead to pin 7 of module connector then drive vehicle at speeds between 40 - 50 mph. 3. Turn speed
control switch to the On position. Voltmeter should read 12 volts. 4. Press and release the speed
control Set button. The voltmeter should indicate from 5 - 9 volts and fluctuate 1 - 2 volts at a rapid
rate. 5. Speed control system should be performing throttle control at this time, maintaining set
speed. If not, replace control module.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Testing and Inspection
Brake Switch (Cruise Control): Testing and Inspection
1. Disconnect six cavity connector from stop lamp switch pigtail. 2. Using an ohmmeter, check
continuity at switch side of connector. 3. With brake pedal released, there should be continuity
between the dark blue/red and yellow/red wires, and between white/pink and white wires.
There should be no continuity between pink and white wires.
4. With brake pedal depressed, there should be continuity between pink and white wires. There
should be no continuity between the dark blue/red
and yellow/red wires, or between white/pink and white wires.
5. If the above results are not obtained the stop lamp switch is defective or out of adjustment.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Locations
Clutch Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Clutch Pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations
Cruise Control Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Brake pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations > Page 5833
Cruise Control Switch: Testing and Inspection
Fig. 6 Speed Control Continuity Chart. 1988-90 Rear Wheel Drive Models
Fig. 7 Speed Control Continuity Chart. 1988-90 Front Wheel Drive Models
Fig. 8 Speed Control Connector Terminal Identification
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations > Page 5834
Fig. 9 Speed Control Continuity Chart. 1991 Models
1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a
continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. 3.
Results should be obtained according to the charts. If these results are not obtained, replace
switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations > Page 5835
Cruise Control Switch: Service and Repair
1. Disconnect battery ground cable. 2. Remove lower steering column cover. 3. Remove four
plastic retaining clips from underside of steering column, then the trough. 4. Disconnect speed
control switch electrical connector from instrument panel harness connector. 5. Remove wiper
control knob from end of turn signal lever, then the silencer from lever. 6. Remove two screws
attaching speed control switch to column. 7. On tilt columns, remove steering wheel, then attach a
flexible guide wire to lower end of speed control switch harness. 8. Remove switch and harness
from column by gently pulling wires through lock housing between lock plate and side of housing.
9. On standard columns, remove attaching screws and the upper steering lock housing cover, then
pull harness up through column.
10. On tilt columns, insert harness connector through turn signal lever opening in column, then pull
upward through upper housing.
11. Attach guide wire to switch wiring harness, then gently pull downward through column opening,
between lock plate and side of housing.
12. On standard columns, insert harness and connector through turn signal lever opening in
column, then pull down and out lower end.
13. On all models, remove slack from all wires.
14. On tilt column, remove guide wires.
15. On all models, install wiring trough with plastic clips.
16. Connect speed control switch electrical connector to instrument panel harness connector.
17. Secure speed control switch to column with two screws.
18. Position silencer on lever, then push wiper control knob in place on end of lever.
19.
On tilt columns, replace steering wheel.
20. On standard columns, install upper steering column lock housing cover.
21. On all models, install lower steering column cover.
22. Connect battery ground cable, then test operation of speed control.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page
5844
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page
5850
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr
> 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr
> 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5859
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5865
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Description and Operation
ABS Light: Description and Operation
The Anti-Lock warning light will normally come on for approximately one to two seconds when the
ignition switch is first turned to the ON position.
Anytime the Controller Anti-Lock Brake (CAB) detects a condition which results in a shutdown of
the ABS function other than when the ignition switch is first turned on it will activate the ABS
warning lamp. When the light is on only the Anti-Lock function of the brake system is affected. The
standard brake system and ability to stop the vehicle will not be affected.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Locations
Audible Warning Device Control Module: Locations
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Locations
Brake Warning Indicator: Locations
Engine Compartment Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Locations > Page 5876
Engine Compartment & Transaxle Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Locations > Page 5877
Brake Warning Indicator: Description and Operation
The brake warning light is designed to light only when either: The parking brake is applied with the ignition key turned "ON".
- One of the two service brake systems has failed.
Bulb Check
The instrument panel bulb can be checked each time the ignition switch is turned to the start
position or the parking brake is set.
Pressure Differential Warning Light Switch
Purpose The function of the Pressure Differential Switch is to alert the driver to a malfunction in the
brake system.
Operation The hydraulic brake system is split diagonally. The left front and right rear brakes are
part of one system and the right front and left rear are part of another.
Both systems are routed through, but hydraulically separated by the Pressure Differential Switch.
If hydraulic pressure is lost in one system, the warning light switch will activate a red light on the
instrument panel, when the brake pedal is depressed. At this point the brakes require service.
- However, since the brake systems are split diagonally the vehicle will retain 50% of its stopping
capability in the event of a failure in either half.
The warning light switch is the latching type. It will automatically recenter itself after the repair is made and the brake pedal Is depressed.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Locations > Page 5878
Brake Warning Indicator: Testing and Inspection
Bulb Check
The instrument panel bulb can be checked each time the ignition switch is turned to the start
position or the parking brake is set.
Pressure Differential Warning Light Switch Circuit Check
1. Raise and support vehicle, then open a wheel cylinder bleeder valve. 2. Press down on brake
pedal and observe brake warning lamp. If lamp fails to illuminate, inspect for the following:
a. Faulty bulb. b. Disconnected electrical socket. c. A broken or disconnected wire at the switch,
located in the brake line "T" fitting, mounted on frame rail in engine compartment below master
cylinder.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Locations
Fig. 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions
Check Gauges Lamp: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 5884
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 5885
Fig. 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Diagram Information and Instructions > Page 5886
Test 12D Repairing The Electro/Mechanical Cluster "NO RESPONSE" Condition
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Page 5887
Check Gauges Lamp: Testing and Inspection
LOW OIL PRESSURE WARMING LAMP/CHECK GAGES TEST
The oil pressure/check gage warning lamp will illuminate under any of the following conditions:
1. Lamp check when the ignition key is turned to the ON position for about two seconds.
2. The oil pressure switch is closed to ground The switch grounds the lamp and is in put to the
body controller which turns on the lamp over the bus.
3. Oil pressure sending unit is high resistance, low pressure. The body controller will turn on lamp
over the bus. The lamp also illuminates when the
engine oil pressure drops below a safe oil pressure level.
To test the system, turn the ignition key to the ON position. If the lamp fails to light, during the two
second lamp, inspect for a burned out lamp or disconnected socket in the cluster.
CONDITION: WARNING LAMP DOES NOT LIGHT
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Page 5888
If the lamp goes out after the lamp check, inspect the connection to the oil pressure switch and
sensor. Check that the wires are going to the correct terminals of the sending unit. Both the switch
and sensor must fail to result in the light going out. If the connector and wiring are OK, use the
DRB II to read the oil pressure switch at the body controller. Disconnect the sending unit connector.
Using an jumper wire, connect one end to the switch terminal and the other to ground. If the lamp
fails to light check for continuity to the cluster and body controller from the pressure switch. Check
for short from pressure sensor circuit to ground. Check the wiring go to the body controller
connector for proper terminals.
CONDITION: LAMP STAYS ON WITH ENGINE RUNNING
If the light stays on with engine running, perform the combination sending unit tests. If the sending
unit is OK perform the following:
1. Using a DRB II monitor the oil pressure switch with the sending unit connector disconnected.
The switch should read open. If it does not, there is
a short in the wiring. Repair as necessary. The circuit goes from the switch to the body controller
and the cluster.
2. Connect the sending unit. Start the engine. Using the DRB II, read the oil pressure level. If the
DRB II reads ignition voltage, there is a open
circuit in the sensor wiring circuit. Repair open circuit.
COMBINATION OIL SENDING UNIT TESTS
The combination oil unit has two functions:
1. The normally closed circuit keeps the oil pressure warning lamp on until there is oil pressure.
2. The sending unit provides a resistance that varies with oil pressure.
3. To test the normally closed oil lamp circuit, disconnect the locking connector and measure the
resistance between the switch terminal and the
metal housing. The ohmmeter should read zero ohms.
4. Start the engine. If there is oil pressure, the ohmmeter should read an open circuit.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Diagrams > Page 5889
5. To test the sending unit, measure the resistance between the sending unit terminal and the
metal housing. The ohmmeter should read open.
6. Start the engine. The ohmmeter should read between 30 and 55 ohms, depending on engine
speed, oil temperature, and oil viscosity.
7. If the switch and sensor read low pressure with the engine running, remove the sending unit.
Connect a pressure gauge in place of the sending unit
to test pressure. For oil pressure specifications, refer to Group 9, Engine. If OK, go to step 8.
8. If the above results are not obtained, replace the switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag System Arming and Disarming
1. Place ignition switch in lock position.
2. Disconnect and tape battery ground cable connector.
3. Wait at least 1 minute after disconnecting battery ground cable before performing any further
repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a
short time even after battery has been disconnected.
4. After repairs are performed, connect battery ground cable.
5. From passenger side of vehicle, turn ignition switch to On position.
6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to
indicate if SRS system is functioning correctly.
7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Locations
Door/Trunk Ajar Indicator/Lamp: Locations
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Dome Lamp Switch
Door Switch: Locations Dome Lamp Switch
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Dome Lamp Switch > Page 5901
Door Switch: Locations Door Ajar Switches
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions
Driver/Vehicle Information Display: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 5906
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 5907
Vehicle Information Center Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light >
Component Information > Locations
Emissions Maintenance Light: Locations
Upper I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light >
Component Information > Locations > Page 5911
Emissions Maintenance Light: Service and Repair
Refer to Powertrain Management/Emission Control Systems/Service and Repair for reset
procedures.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection
Fuel Gauge: Testing and Inspection
Fuel Gauge Pins
Fuel Gauge Pins - Optional Cluster
1. Remove fuel gauge from the cluster. 2. Check for continuity in wire between fuel tank sending
unit and gauge (fuel level input pin). 3. With ignition switch in On position, check for battery voltage
across B+ pin and ground pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Locations
Fuel Gauge Sender: Locations
Top Of Fuel Tank
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Locations > Page 5918
Fuel Gauge Sender: Testing and Inspection
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit.
1. Disconnect wiring from fuel tank sending unit. 2. Connect wiring to a known good sending unit. 3.
Connect a jumper wire between sending unit pick up tube and ground.
Fuel Tank Sending Unit (Typical)
4. Check fuel gauge as follows: Allow at least two minutes for gauge to settle at each test point.
a. Move and clip float arm to its empty stop and turn ignition to the On position, gauge should read
Empty or below. b. Move and clip float arm to the Full position, gauge should read Full or above.
5. If gauge does not meet specifications, check the following items for possible malfunction:
a. Wiring and connections between gauge sending unit and multiple connector behind left kick
panel. b. Wiring and connections between multiple connector and printed circuit board terminals. c.
Circuit continuity between printed circuit board terminals and gauge terminals. If the above items
are satisfactory, the gauge is defective
and must be replaced.
6. If fuel gauge meets specifications check original fuel tank sending unit as follows:
a. Remove fuel tank sending unit from fuel tank and connect a jumper wire between sending unit
pick up tube and ground.
7. Repeat step 4. 8. If fuel gauge is now within specifications, check the following as possible
cause:
a. Ground wire from sending unit to left side cowl for continuity. b. Sending unit deformed. Ensure
float arm moves freely and pick up tube is not bent. c. Inspect float. d. Sending unit improperly
installed. Install correctly. e. Mounting flange on fuel tank for sending unit deformed. f.
Fuel tank bottom deformed causing improper positioning of pick-up tube.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag System Arming and Disarming
1. Place ignition switch in lock position.
2. Disconnect and tape battery ground cable connector.
3. Wait at least 1 minute after disconnecting battery ground cable before performing any further
repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a
short time even after battery has been disconnected.
4. After repairs are performed, connect battery ground cable.
5. From passenger side of vehicle, turn ignition switch to On position.
6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to
indicate if SRS system is functioning correctly.
7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions
Instrument Panel Circuit Board: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5927
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5928
Instrument Panel Circuit Board: Connector Views
Printed Circuit Board Connector
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5929
Printed Circuit Board Connector. Mechanical Cluster Less Tach
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5930
Printed Circuit Board Connector. Warning Light Module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5931
Instrument Panel Circuit Board: Electrical Diagrams
Printed Circuit Board. Mechanical Cluster Less Tach
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5932
Printed Circuit Board. Mechanical Cluster w/Tach
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5933
Printed Circuit Board. Warning Light Module
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Low Fuel
Indicator Relay > Component Information > Locations
Low Fuel Indicator Relay: Locations
Low Fuel Relay
The low fuel relay is located on the back of the instrument cluster, behind the message center.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
On-Board Diagnosis Connector Location
On-Board Diagnosis Connector Location
On-Board Diagnosis Connector Location
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation > Page 5941
On-Board Diagnosis Connector Location
On-Board Diagnosis Connector Location
This reminder system uses ignition on time to calculate maintenance intervals. After necessary
emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the
on-board diagnostic connector. Follow instructions indicated by DRB II tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation > Page 5942
Maintenance Required Lamp/Indicator: Service and Repair
On-Board Diagnosis Connector Location
On certain models, this Emission Maintenance Reminder System is incorporated into the engine
controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000,
82,500 or 120,000 miles it will illuminate the EMR lamp. When the indicated mileage is reached or
the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset.
1. At 60,00 miles, proceed as follows:
a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve.
2. At 82,500 miles, proceed as follows:
a. Replace oxygen sensor.
3. At 120,000 miles, proceed as follows:
a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve.
4. On 1990-95 models, after necessary emission maintenance has been performed, connect
Diagnosis Read-Out Box II (DRB II) to the on-board
diagnosis connector. See images above.
5. On all models, Follow instructions indicated by DRB II tool.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Malfunction
Indicator Lamp Driver Module > Component Information > Locations
Malfunction Indicator Lamp Driver Module: Locations
Upper I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Diagrams > Diagram Information and Instructions
Oil Pressure Gauge: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Diagrams > Diagram Information and Instructions > Page 5951
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Diagrams > Diagram Information and Instructions > Page 5952
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Diagrams > Page 5953
Oil Pressure Gauge: Description and Operation
The oil pressure indicating system consists of an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuates the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, increasing current flow to the gauge, resulting in an increased gauge reading.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Diagrams > Page 5954
Oil Pressure Gauge: Testing and Inspection
Oil Pressure Gauge Pins
Combination Oil Pressure Sending Unit
1. Remove oil pressure gauge assembly from the cluster. 2. Check for continuity in wire between
oil pressure sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check
for battery voltage across B+ pin and ground pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
Lower LH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions
Oil Pressure Sender: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 5960
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams > Diagram Information and Instructions > Page 5961
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
I/P, Cowl & Steering Column Components
LH Kickpanel On Park Brake Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Locations
Audible Warning Device Control Module: Locations
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Low Fuel Indicator Relay > Component Information > Locations
Low Fuel Indicator Relay: Locations
Low Fuel Relay
The low fuel relay is located on the back of the instrument cluster, behind the message center.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Malfunction Indicator Lamp Driver Module > Component Information > Locations
Malfunction Indicator Lamp Driver Module: Locations
Upper I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Locations > Dome Lamp Switch
Door Switch: Locations Dome Lamp Switch
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Locations > Dome Lamp Switch > Page 5980
Door Switch: Locations Door Ajar Switches
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Locations
Fuel Gauge Sender: Locations
Top Of Fuel Tank
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Locations > Page 5984
Fuel Gauge Sender: Testing and Inspection
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit.
1. Disconnect wiring from fuel tank sending unit. 2. Connect wiring to a known good sending unit. 3.
Connect a jumper wire between sending unit pick up tube and ground.
Fuel Tank Sending Unit (Typical)
4. Check fuel gauge as follows: Allow at least two minutes for gauge to settle at each test point.
a. Move and clip float arm to its empty stop and turn ignition to the On position, gauge should read
Empty or below. b. Move and clip float arm to the Full position, gauge should read Full or above.
5. If gauge does not meet specifications, check the following items for possible malfunction:
a. Wiring and connections between gauge sending unit and multiple connector behind left kick
panel. b. Wiring and connections between multiple connector and printed circuit board terminals. c.
Circuit continuity between printed circuit board terminals and gauge terminals. If the above items
are satisfactory, the gauge is defective
and must be replaced.
6. If fuel gauge meets specifications check original fuel tank sending unit as follows:
a. Remove fuel tank sending unit from fuel tank and connect a jumper wire between sending unit
pick up tube and ground.
7. Repeat step 4. 8. If fuel gauge is now within specifications, check the following as possible
cause:
a. Ground wire from sending unit to left side cowl for continuity. b. Sending unit deformed. Ensure
float arm moves freely and pick up tube is not bent. c. Inspect float. d. Sending unit improperly
installed. Install correctly. e. Mounting flange on fuel tank for sending unit deformed. f.
Fuel tank bottom deformed causing improper positioning of pick-up tube.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Parking Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
I/P, Cowl & Steering Column Components
LH Kickpanel On Park Brake Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component
Information > Testing and Inspection
Fig. 1 Speedometer & cable diagnosis.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Description and Operation
Speedometer Head: Description and Operation
Information in this database covers only service on speedometers which can be performed by the
average service man. Repairs on the units themselves are not included as they require special tools and extreme care
when making repairs and adjustments and only an experienced speedometer mechanic should
attempt such servicing.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Description and Operation > Page 5994
Fig. 1 Speedometer & cable diagnosis.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection
Tachometer: Testing and Inspection
1. Remove instrument cluster. 2. with ignition switch in On position, check for battery voltage at
cavity "F" of instrument cluster right side (black) connector and cavity "A" of
instrument panel cluster left side (red) connector.
3. Check cavity "H" of instrument cluster left side connector for continuity to ground. 4. Check for
tachometer signal from the engine controller by connecting an AC Digital Voltmeter to cavity "D" of
the black instrument cluster
connector and ground. A minimum of 1 volt should be present with engine running.
5. If there is less than 1 volt present in above step, check for continuity between cavity "D" of
instrument cluster and pin 43 of engine controller
connector. If there is no continuity, repair wire as required. Also check connector at engine
controller for damaged pins or terminal push outs.
6. If voltage reading from step 5 is less than 1 volts and no continuity between cavity "D" and pin 43
is evident, replace the engine controller. 7. If above tests are correct, replace the tachometer drive
module. 8. If tachometer continues to be inoperable, replace the tachometer assembly.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Description and Operation
Temperature Gauge: Description and Operation
This system consists of a sending unit, electrical temperature gauge and an instrument voltage
regulator. As engine temperature increases or decreases, resistance of the sending unit changes,
in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the
sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature.
As engine temperature increases, resistance of the sending unit decreases, permitting an
increased current flow to the gauge, resulting in an increased temperature reading.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis
Temperature Gauge: Testing and Inspection Temperature Gauge Diagnosis
Fig. 1 Cooling System Diagnosis (Part 1 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6003
Fig. 1 Cooling System Diagnosis (Part 2 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6004
Fig. 1 Cooling System Diagnosis (Part 3 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6005
Fig. 1 Cooling System Diagnosis (Part 4 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6006
Fig. 1 Cooling System Diagnosis (Part 5 of 5)
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6007
Temperature Gauge: Testing and Inspection Temperature Gauge Test
Temperature Gauge Pins
1. Remove temperature gauge assembly from the cluster. 2. Check for continuity in wire between
temperature sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check
for battery voltage across B+ pin and ground pin.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Locations
Temperature Sensor (Gauge): Locations
Top RH Side Of Engine
Applicable to: 1989 V6-181/3.0L Engine
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Diagram Information and Instructions
Temperature Sensor (Gauge): Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Diagram Information and Instructions > Page 6013
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Diagram Information and Instructions > Page 6014
Oil Pressure & Temperature System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Diagrams > Page 6015
Temperature Sensor (Gauge): Testing and Inspection
When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the
gauge, check for a defective sending unit or wiring as follows:
1. Ground sending unit connector leads, at the sending unit, in the vehicle.
2. With ignition in On position, a grounded input will cause the fuel or temperature gauge to read
maximum or above.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component
Information > Description and Operation
Volt Meter Gauge: Description and Operation
The voltmeter gauge measures electrical flow from the battery to indicate battery output tolerances.
The voltmeter reading can range from 13.5-14.0 volts under normal operating conditions.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component
Information > Description and Operation > Page 6019
Volt Meter Gauge: Testing and Inspection
Voltmeter Pins
1. Remove voltmeter assembly from cluster. 2. Connect a volt/ohmmeter between the B+ pin and
the Ground pin. Turn the ignition switch to the ON position and check meter reading.
^ The instrument panel voltmeter indicates regulated alternator output or battery voltage, which
ever is greater.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information >
Locations > 4 Speed A/T
Backup Lamp Relay: Locations 4 Speed A/T
Engine Compartment.
The Backup Lamp Relay is located in the right rear corner of the engine compartment, on the side
shield.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > 3 Speed A/T
Backup Lamp Switch: Locations 3 Speed A/T
Neutral/Park Safety Switch
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams > Diagram Information and Instructions
Backup Lamp Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6032
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6033
Backup Lamp Switch: Electrical Diagrams
3 Speed A/T
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
4 Speed A/T
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6034
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6035
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Description and Operation > 3 Speed A/T
Backup Lamp Switch: Description and Operation 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
- It provides ground for the starter solenoid circuit through the selector lever in only Park and
Neutral positions.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Testing and Inspection > 3 Speed A/T
Backup Lamp Switch: Testing and Inspection 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Service and Repair > 3 Speed A/T
Backup Lamp Switch: Service and Repair 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Brake Light Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Brake pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram
Information and Instructions
Brake Light Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6047
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6048
Speed Control & Stop Lamp Switch Wiring Circuit SH-25
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 6049
Brake Light Switch: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then
remove switch assembly. 3. Install new switch and connect switch electrical connector. If
adjustment of switch is required, proceed as follows:
a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull back on
brake pedal until it will go back no further. This will cause switch to ratchet backward into correct
position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams >
Diagram Information and Instructions
Center Mounted Brake Lamp: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 6054
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 6055
Center Mounted Brake Lamp: Electrical Diagrams
Courtesy & Dome Lamps Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 6056
Courtesy & Dome Lamps Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Courtesy Lamp: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6061
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6062
Courtesy Lamp: Electrical Diagrams
Courtesy & Dome Lamps Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6063
Courtesy & Dome Lamps Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6064
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6065
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Switch > Component Information > Locations
Dome Lamp Switch: Locations
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Dome Lamp Switch
Door Switch: Locations Dome Lamp Switch
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Dome Lamp Switch
> Page 6074
Door Switch: Locations Door Ajar Switches
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations
Hazard Flasher
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions
Hazard Warning Flasher: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions > Page 6081
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions > Page 6082
Hazard Warning Flasher: Electrical Diagrams
Hazard Flasher & Stop/Turn Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Diagrams > Diagram Information and Instructions > Page 6083
Hazard Flasher & Stop/Turn Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Service and Repair
Hazard Warning Switch: Service and Repair
1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering
wheel.
Steering column cover, silencer & reinforcement removal
3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot
in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever
electrical connectors. 6. On models equipped with standard column, proceed as follows:
a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove
washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to
washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then
remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws.
7. On models equipped with tilt column, proceed as follows:
a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove
ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control
lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control
lever shaft to full clockwise position, then remove shaft from washer/wiper switch.
Lock plate removal. Models w/tilt column
e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring
out of groove with a suitable screwdriver.
The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will
turn too easily and make removal difficult.
f. Remove lock plate, cancelling cam and upper bearing spring.
g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard
switch attaching screws, Place shift bowl in Low position.
Turn signal switch replacement
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Service and Repair > Page 6087
8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up
from column while straightening and guiding wires
up through column opening.
9. Reverse procedure to install. Rearm airbag system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations
Headlamp Dimmer Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Diagram Information and Instructions
Headlamp Dimmer Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6094
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6095
Headlamp Dimmer Switch: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6096
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 6097
Headlamp Dimmer Switch: Service and Repair
Dimmer switch replacement
1. Disconnect battery ground cable. 2. Remove left lower instrument panel cover, then tape dimmer
switch rod to steering column to prevent rod from falling out of notch in actuator
lever.
3. Remove switch to column attaching screws. 4. Disconnect switch electrical connector, then
remove switch from steering column. 5. Reverse procedure to install. During installation, gently
push up on switch to take up slack on rod.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
Headlamp Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6103
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6104
Headlamp Switch: Electrical Diagrams
Headlamp Switch & Horn System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6105
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6106
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 6107
Headlamp Switch: Service and Repair
Headlamp switch removal
1. Disconnect battery ground cable. 2. Remove headlight and accessory switch trim bezel. 3.
Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then
disconnect switch electrical connectors. 5. Remove switch knob and stem by depressing button on
switch. 6. Remove two headlight switch plate to switch plate assembly attaching screws, then the
headlight switch retainer and switch. 7. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and
Instructions
Horn: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and
Instructions > Page 6112
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and
Instructions > Page 6113
Horn: Electrical Diagrams
Headlamp Switch & Horn System Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and
Instructions > Page 6114
Headlamp Switch & Horn System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 6119
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 6120
Interior Lighting Module: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 6121
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram
Information and Instructions
Interior Lighting Relay: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram
Information and Instructions > Page 6126
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram
Information and Instructions > Page 6127
Interior Lighting Relay: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram
Information and Instructions > Page 6128
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > 4 Speed A/T
Backup Lamp Relay: Locations 4 Speed A/T
Engine Compartment.
The Backup Lamp Relay is located in the right rear corner of the engine compartment, on the side
shield.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 6138
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 6139
Interior Lighting Module: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 6140
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Relay: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 6145
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 6146
Interior Lighting Relay: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 6147
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Lighting Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 6152
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 6153
Trailer Lighting Module: Electrical Diagrams
Rear Lighting & Trailer Tow Wiring Circuit SH-68 - Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 6154
Rear Lighting & Trailer Tow Wiring Circuit SH-79 - Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > 3 Speed A/T
Backup Lamp Switch: Locations 3 Speed A/T
Neutral/Park Safety Switch
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions
Backup Lamp Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6162
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6163
Backup Lamp Switch: Electrical Diagrams
3 Speed A/T
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
4 Speed A/T
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6164
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6165
Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at
the vehicle level. See: Diagrams/Electrical Diagrams
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Description and Operation > 3 Speed A/T
Backup Lamp Switch: Description and Operation 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
The neutral starting switch is the center terminal of the 3 terminal switch.
- It provides ground for the starter solenoid circuit through the selector lever in only Park and
Neutral positions.
The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Testing and Inspection > 3 Speed A/T
Backup Lamp Switch: Testing and Inspection 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Service and Repair > 3 Speed A/T
Backup Lamp Switch: Service and Repair 3 Speed A/T
Neutral Starting And Back-Up Lamp Switch
Replacement And Test
1. To test switch, remove wiring connector from switch and test for continuity between center pin of
switch and transaxle case.
Continuity should exist only when transaxle is in Park or Neutral.
2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch
from transaxle case allowing fluid to drain into a container.
Move selector lever to Park and then to Neutral positions, and inspect to see that the switch
operating lever fingers are centered in switch opening in the case.
4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.).
Retest switch with the test lamp.
5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through
the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from
switch and test for continuity between the two outside pins. 8. Continuity should exist only with
transaxle in Reverse position. 9. No continuity should exist from either pin to the case.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Brake pedal Bracket
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions
Brake Light Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6177
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6178
Speed Control & Stop Lamp Switch Wiring Circuit SH-25
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Page 6179
Brake Light Switch: Service and Repair
1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then
remove switch assembly. 3. Install new switch and connect switch electrical connector. If
adjustment of switch is required, proceed as follows:
a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull back on
brake pedal until it will go back no further. This will cause switch to ratchet backward into correct
position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Dome Lamp Switch >
Component Information > Locations
Dome Lamp Switch: Locations
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Dome Lamp Switch
Door Switch: Locations Dome Lamp Switch
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Dome Lamp Switch > Page 6187
Door Switch: Locations Door Ajar Switches
Front Body Components
In Respective Door Jamb
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Service and Repair
Hazard Warning Switch: Service and Repair
1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering
wheel.
Steering column cover, silencer & reinforcement removal
3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot
in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever
electrical connectors. 6. On models equipped with standard column, proceed as follows:
a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove
washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to
washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then
remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws.
7. On models equipped with tilt column, proceed as follows:
a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove
ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control
lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control
lever shaft to full clockwise position, then remove shaft from washer/wiper switch.
Lock plate removal. Models w/tilt column
e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring
out of groove with a suitable screwdriver.
The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will
turn too easily and make removal difficult.
f. Remove lock plate, cancelling cam and upper bearing spring.
g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard
switch attaching screws, Place shift bowl in Low position.
Turn signal switch replacement
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Service and Repair > Page 6191
8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up
from column while straightening and guiding wires
up through column opening.
9. Reverse procedure to install. Rearm airbag system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch
> Component Information > Locations
Headlamp Dimmer Switch: Locations
I/P, Cowl & Steering Column Components
Top Of Steering Column
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch
> Component Information > Diagrams > Diagram Information and Instructions
Headlamp Dimmer Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 6197
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 6198
Headlamp Dimmer Switch: Electrical Diagrams
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 6199
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch
> Component Information > Diagrams > Page 6200
Headlamp Dimmer Switch: Service and Repair
Dimmer switch replacement
1. Disconnect battery ground cable. 2. Remove left lower instrument panel cover, then tape dimmer
switch rod to steering column to prevent rod from falling out of notch in actuator
lever.
3. Remove switch to column attaching screws. 4. Disconnect switch electrical connector, then
remove switch from steering column. 5. Reverse procedure to install. During installation, gently
push up on switch to take up slack on rod.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
Headlamp Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6206
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6207
Headlamp Switch: Electrical Diagrams
Headlamp Switch & Horn System Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6208
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6209
Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 6210
Headlamp Switch: Service and Repair
Headlamp switch removal
1. Disconnect battery ground cable. 2. Remove headlight and accessory switch trim bezel. 3.
Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then
disconnect switch electrical connectors. 5. Remove switch knob and stem by depressing button on
switch. 6. Remove two headlight switch plate to switch plate assembly attaching screws, then the
headlight switch retainer and switch. 7. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Technical Service Bulletins > Turn Signal Switch - Canceling Pin Indexing
Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Canceling Pin Indexing
Models
1988 & 1989 AA-, AB-, AC-, AD-, AG-, AH-, AJ-, AK-, AL-, AM-, AN-, & AP-Body Equipped With
Non-tilt Steering Column
Subject
Turn Signal Switch Canceling
Index
ELECTRICAL
Date
January 30, 1989
No.
08-03-89
P-196
(C08-03-9) BODY CODE LEGEND
AA - Spirit/Acclaim AK - Aries/Reliant
AB - Dodge Ram/Van Wagon AL - Omni/Horizon
AC - Dynasty/New Yorker/Landau AM - Diplomat/Gran Fury/
AD - Dodge Ram Pickup/ Fifth Avenue
Ramcharger Sport Utility AN - Dodge Dakota/
AG - Daytona Dakota/Sport
AH - Lancer/LeBaron GTS AP - Shadow/Sundance
AJ - Lebaron
SYMPTOM/CONDITION
Turn signals do not cancel properly after the steering wheel has been removed and reinstalled.
REPAIR PROCEDURE
Anytime the steering wheel is removed and replaced on nontilt columns, there is the possibility that
the turn signals will not cancel properly until the pin in the steering wheel is properly indexed with
respect to the turn signal switch.
The following procedure should be used to ensure the turn signal cancel feature operates correctly.
1. Engage the turn signal lever in either the right turn or the left turn position.
2. While holding the turn signal lever to prevent movement, rotate the steering wheel two complete
turns (or until the wheel stops) in the direction opposite the direction of the turn signal lever.
Example: If the turn signal lever is moved downward to the left, rotate the steering wheel to the
right. If the turn signal lever was moved upward to the right, then rotate the steering wheel to the
left.
3. Release the turn signal lever and then return the steering wheel to the straight ahead position.
4. To check for proper canceling operation, engage the turn signal lever and then turn the steering
wheel at least one-half revolution in the same direction in which the turn signal switch is engaged.
5. Return the steering wheel to the straight ahead position. The turn signal switch should cancel at
this time.
6. Repeat Steps 4 and 5 to check the cancel feature in the opposite direction.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Technical Service Bulletins > Page 6215
Turn Signal Switch: Service and Repair
Turn Signal/Hazard Warning Switch
1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering
wheel.
Steering column cover, silencer & reinforcement removal
3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot
in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever
electrical connectors. 6. On models equipped with standard column, proceed as follows:
a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove
washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to
washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then
remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws.
7. On models equipped with tilt column, proceed as follows:
a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove
ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control
lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control
lever shaft to full clockwise position, then remove shaft from washer/wiper switch.
Lock plate removal. Models w/tilt column
e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring
out of groove with a suitable screwdriver.
The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will
turn too easily and make removal difficult.
f. Remove lock plate, cancelling cam and upper bearing spring.
g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard
switch attaching screws, Place shift bowl in Low position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Technical Service Bulletins > Page 6216
Turn signal switch replacement
8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up
from column while straightening and guiding wires
up through column opening.
9. Reverse procedure to install. Rearm airbag system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions
Trailer Lighting Module: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 6221
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 6222
Trailer Lighting Module: Electrical Diagrams
Rear Lighting & Trailer Tow Wiring Circuit SH-68 - Part 2
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 6223
Rear Lighting & Trailer Tow Wiring Circuit SH-79 - Part 1
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Locations
Turn Signal Flasher
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical
Service Bulletins > Turn Signal Switch - Canceling Pin Indexing
Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Canceling Pin Indexing
Models
1988 & 1989 AA-, AB-, AC-, AD-, AG-, AH-, AJ-, AK-, AL-, AM-, AN-, & AP-Body Equipped With
Non-tilt Steering Column
Subject
Turn Signal Switch Canceling
Index
ELECTRICAL
Date
January 30, 1989
No.
08-03-89
P-196
(C08-03-9) BODY CODE LEGEND
AA - Spirit/Acclaim AK - Aries/Reliant
AB - Dodge Ram/Van Wagon AL - Omni/Horizon
AC - Dynasty/New Yorker/Landau AM - Diplomat/Gran Fury/
AD - Dodge Ram Pickup/ Fifth Avenue
Ramcharger Sport Utility AN - Dodge Dakota/
AG - Daytona Dakota/Sport
AH - Lancer/LeBaron GTS AP - Shadow/Sundance
AJ - Lebaron
SYMPTOM/CONDITION
Turn signals do not cancel properly after the steering wheel has been removed and reinstalled.
REPAIR PROCEDURE
Anytime the steering wheel is removed and replaced on nontilt columns, there is the possibility that
the turn signals will not cancel properly until the pin in the steering wheel is properly indexed with
respect to the turn signal switch.
The following procedure should be used to ensure the turn signal cancel feature operates correctly.
1. Engage the turn signal lever in either the right turn or the left turn position.
2. While holding the turn signal lever to prevent movement, rotate the steering wheel two complete
turns (or until the wheel stops) in the direction opposite the direction of the turn signal lever.
Example: If the turn signal lever is moved downward to the left, rotate the steering wheel to the
right. If the turn signal lever was moved upward to the right, then rotate the steering wheel to the
left.
3. Release the turn signal lever and then return the steering wheel to the straight ahead position.
4. To check for proper canceling operation, engage the turn signal lever and then turn the steering
wheel at least one-half revolution in the same direction in which the turn signal switch is engaged.
5. Return the steering wheel to the straight ahead position. The turn signal switch should cancel at
this time.
6. Repeat Steps 4 and 5 to check the cancel feature in the opposite direction.
POLICY: Information only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical
Service Bulletins > Page 6232
Turn Signal Switch: Service and Repair
Turn Signal/Hazard Warning Switch
1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering
wheel.
Steering column cover, silencer & reinforcement removal
3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot
in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever
electrical connectors. 6. On models equipped with standard column, proceed as follows:
a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove
washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to
washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then
remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws.
7. On models equipped with tilt column, proceed as follows:
a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove
ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control
lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control
lever shaft to full clockwise position, then remove shaft from washer/wiper switch.
Lock plate removal. Models w/tilt column
e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring
out of groove with a suitable screwdriver.
The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will
turn too easily and make removal difficult.
f. Remove lock plate, cancelling cam and upper bearing spring.
g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard
switch attaching screws, Place shift bowl in Low position.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical
Service Bulletins > Page 6233
Turn signal switch replacement
8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up
from column while straightening and guiding wires
up through column opening.
9. Reverse procedure to install. Rearm airbag system.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Underhood Lamp: Diagram Information and Instructions
Symbol Identification
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6238
How to Read Wiring Diagrams
Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG
Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6239
Underhood Lamp Wiring Circuit
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component
Information > Locations
Heated Glass Element Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Locations
Heated Glass Element Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations
Power Window Switch: Locations
Front Door Components
In Front Door Armrest
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Power Window Switch Test
Power Window Switch: Testing and Inspection Power Window Switch Test
Left Power Window Switch Continuity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Power Window Switch Test > Page 6254
Right Power Window Switch Continuity
1. If the failure is in the right side door, remove the right power window switch from the door trim
panel.
2. Connect jumper wires to the right power window switch connector as shown. The jumper wires
take the place of a good switch in the inactive position.
3. Using the drivers side power window switch, activate the windows up and down. If the power
windows now operate properly, replace the passenger side switch. If the power windows still do not
operate, go to step 4.
4. Remove the drivers side power window switch from the door trim panel.
5. Connect jumper wires to the power window switch electrical connector as shown. If the power
window system operates with the jumper wires connected, the power window switch is defective
and needs to be replaced. If the power window system doesn't work with the jumper wires
connected, check the wiring harness from the switch to the window lift motor for an open circuit.
See: Windows/Power Window Motor/Testing and Inspection/Window Lift Motor Test
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Power Window Switch Test > Page 6255
Power Window Switch: Testing and Inspection Switch Voltage Test
Left Power Window Switch Continuity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Power Window Switch Test > Page 6256
Right Power Window Switch Continuity
NOTE: The following test determines whether voltage is continuous through the wiring harness to
the power window switch.
1. Remove the power window switch from the door trim panel.
2. Separate the multiple terminal block on the wiring harness from the power window switch.
3. Connect one lead of a test light to the black wire terminal and the other lead to the tan wire
terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning
properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check
for an open in the wiring harness.
4. If the wiring circuit is functioning properly, See: Windows/Power Window Motor/Testing and
Inspection/Window Lift Motor Test
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 6257
Power Window Switch: Service and Repair
1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect
wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair
Front Door Window Motor: Service and Repair
Power Window Regulator Assembly
REMOVAL
1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair
2. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair
3. Remove the power window regulator assembly. See: Window Regulator/Service and
Repair/Power Window Regulator Replacement
4. Drill out the two (2) rivets mounting the power window lift motor to the window regulator.
5. Remove the power window lift motor off of the regulator.
INSTALLATION
1. Position the power window lift motor onto the power window regulator and install two (2) 1/4-20
X 1/2 screws in place of the rivets that were drilled out for removal. Torque the mounting screws to
90 lb-ft (11 Nm).
2. Install the power window regulator assembly. See: Window Regulator/Service and Repair/Power
Window Regulator Replacement
3. Install the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair
4. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations
Power Window Switch: Locations
Front Door Components
In Front Door Armrest
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Power Window Switch Test
Power Window Switch: Testing and Inspection Power Window Switch Test
Left Power Window Switch Continuity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Power Window Switch Test > Page 6268
Right Power Window Switch Continuity
1. If the failure is in the right side door, remove the right power window switch from the door trim
panel.
2. Connect jumper wires to the right power window switch connector as shown. The jumper wires
take the place of a good switch in the inactive position.
3. Using the drivers side power window switch, activate the windows up and down. If the power
windows now operate properly, replace the passenger side switch. If the power windows still do not
operate, go to step 4.
4. Remove the drivers side power window switch from the door trim panel.
5. Connect jumper wires to the power window switch electrical connector as shown. If the power
window system operates with the jumper wires connected, the power window switch is defective
and needs to be replaced. If the power window system doesn't work with the jumper wires
connected, check the wiring harness from the switch to the window lift motor for an open circuit.
See: Power Window Motor/Testing and Inspection/Window Lift Motor Test
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Power Window Switch Test > Page 6269
Power Window Switch: Testing and Inspection Switch Voltage Test
Left Power Window Switch Continuity
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Power Window Switch Test > Page 6270
Right Power Window Switch Continuity
NOTE: The following test determines whether voltage is continuous through the wiring harness to
the power window switch.
1. Remove the power window switch from the door trim panel.
2. Separate the multiple terminal block on the wiring harness from the power window switch.
3. Connect one lead of a test light to the black wire terminal and the other lead to the tan wire
terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning
properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check
for an open in the wiring harness.
4. If the wiring circuit is functioning properly, See: Power Window Motor/Testing and
Inspection/Window Lift Motor Test
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 6271
Power Window Switch: Service and Repair
1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect
wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair
Front Door Window Glass: Service and Repair
Glass To Regulator
REMOVAL
1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair
2. Raise the door glass until the two (2) nuts align with access holes in the inner door panel.
3. Remove the two (2) glass plate nuts that hold the door glass to the front window regulator
assembly.
4. Remove the glass through the belt opening, using the notch at the rear of the door to clear the
glass fasteners (pull the glass towards the inside of the vehicle when removing).
INSTALLATION
1. Slide the door glass into the door through the belt opening, using the notch at the rear of the
door to clear the glass fasteners.
2. Install the two (2) glass plate nuts that hold the door glass to the front window regulator
assembly and tighten finger tight.
3. To adjust the door glass, raise glass to full up position and secure glass attaching nuts.
3. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical
Service Bulletins > Customer Interest for Window Regulator: > 232993 > Jun > 93 > Window Regulator - Inoperative
Window Regulator: Customer Interest Window Regulator - Inoperative
NO.: 23-29-93
GROUP: Body
EFFECTIVE DATE: Jun 4, 1993
SUBJECT: Drum And Cable Window Regulator Retrofit Procedure
MODELS:
1989-1990 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1984-1988 (S) Caravan/Grand Caravan/Voyager/Grand Voyager
SYMPTOM/CONDITION:
The window regulator may become inoperative due to the flex track portion of the window regulator
being damaged.
DIAGNOSIS:
Inspect the flex track portion of the window regulator for damage or mis-positioning.
PARTS REQUIRED:
Each Manual Regulator Package Consists of: 1
Window Regulator
1 Screw & Washer Assembly, Upper Regulator to Door Attachment
6 Screw, Regulator to Door Attachment
1 Template, Window Regulator Retrofit
1 Instruction Sheet
REPAIR PROCEDURE:
This bulletin involves replacing flex track style window regulator(s) with drum and cable style
window regulator(s).
NOTE: WHEN REMOVING THE RIVETS ATTACHING THE REGULATOR TO THE DOOR, DO
NOT USE A DRILL BIT LARGER THAN 1/4 IN.
1. Using the appropriate steps of the procedure outlined in section 23 of the applicable service
manual, remove the damaged window regulator(s). Save the hardware attaching the glass to the
regulator for use at reassembly.
2. Remove all debris from inside the door shell.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical
Service Bulletins > Customer Interest for Window Regulator: > 232993 > Jun > 93 > Window Regulator - Inoperative > Page
6284
3. Use the reference holes of the template (P/N K4746908) to properly position the template on the
front door(s) inner panel then tape the template in place. Refer to Figure 1.
4. Center punch and drill, 7.9 mm (5/16 in.) holes identified with an * (asterisk) on the template.
Four are for the regulator cable guide bar and three are for the motor attachment (if the vehicle is
equipped with electric windows).
NOTE: IN THE NEXT STEP, BE CAREFUL NOT TO TWIST THE CABLES OF THE WINDOW
REGULATOR ASSEMBLY.
5. Position the new drum and cable window regulator in the door and attach the cable guide bar
with 5 screws (4 - P/N 6501682 and 1 - P/N 6100557) which is used at the up stop position. The
top screw should be left loose for now and tightened when making the final adjustment to the
up-stop in step 10.
6. A) For electric regulator equipped vehicles, attach the motor to the inner door panel using 3 nut &
washer assemblies (P/N 6100048).
B) For manual regulator equipped vehicles, attach the manual drive assembly to the inner door
panel with 2 screws (P/N 6501682).
7. Using the original hardware, attach the glass to the regulator.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical
Service Bulletins > Customer Interest for Window Regulator: > 232993 > Jun > 93 > Window Regulator - Inoperative > Page
6285
8. If the vehicle is electric regulator equipped, locate the wiring harness extension package (P/N
K4746909). Determine which insulator in the package needs to be installed to the door harness
end of the wiring harness extension (black for 1988 and prior, red for 1989 and 1990). Referring to
Figure 2 for proper wire to insulator orientation, assemble the appropriate insulator to the wiring
harness extension. If the red insulator is used, the wedge must be installed in the terminal end of
the insulator and xmas tree fastener must be inserted into the slot on the side of the red insulator.
9. Install the wiring harness extension (P/N K4746909). Use the xmas tree fasteners of the
insulators to secure the harness to the door, refer to Figure 3. At the forward attachment point, the
insulator must be installed so it is inside the door cavity. At mid-door attachment, install the
insulator so it is outside the door cavity. Bend the tab back into the door so the insulator becomes
flush to slightly underflush with the inner door panel.
10. Verify the proper operation of the window. Adjust as necessary. Tighten the upstop screw.
11. Reinstall the door trim.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical
Service Bulletins > Customer Interest for Window Regulator: > 232993 > Jun > 93 > Window Regulator - Inoperative > Page
6286
TIME ALLOWANCE: Labor Operation No.
23-34-10-96 Power Window Regulator 1.0 Hrs.
23-34-10-97 Manual Window Regulator 0.9 Hrs.
FAILURE CODE: 27 - Damaged
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Window Regulator: > 232993 > Jun > 93 > Window Regulator Inoperative
Window Regulator: All Technical Service Bulletins Window Regulator - Inoperative
NO.: 23-29-93
GROUP: Body
EFFECTIVE DATE: Jun 4, 1993
SUBJECT: Drum And Cable Window Regulator Retrofit Procedure
MODELS:
1989-1990 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country
1984-1988 (S) Caravan/Grand Caravan/Voyager/Grand Voyager
SYMPTOM/CONDITION:
The window regulator may become inoperative due to the flex track portion of the window regulator
being damaged.
DIAGNOSIS:
Inspect the flex track portion of the window regulator for damage or mis-positioning.
PARTS REQUIRED:
Each Manual Regulator Package Consists of: 1
Window Regulator
1 Screw & Washer Assembly, Upper Regulator to Door Attachment
6 Screw, Regulator to Door Attachment
1 Template, Window Regulator Retrofit
1 Instruction Sheet
REPAIR PROCEDURE:
This bulletin involves replacing flex track style window regulator(s) with drum and cable style
window regulator(s).
NOTE: WHEN REMOVING THE RIVETS ATTACHING THE REGULATOR TO THE DOOR, DO
NOT USE A DRILL BIT LARGER THAN 1/4 IN.
1. Using the appropriate steps of the procedure outlined in section 23 of the applicable service
manual, remove the damaged window regulator(s). Save the hardware attaching the glass to the
regulator for use at reassembly.
2. Remove all debris from inside the door shell.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Window Regulator: > 232993 > Jun > 93 > Window Regulator Inoperative > Page 6292
3. Use the reference holes of the template (P/N K4746908) to properly position the template on the
front door(s) inner panel then tape the template in place. Refer to Figure 1.
4. Center punch and drill, 7.9 mm (5/16 in.) holes identified with an * (asterisk) on the template.
Four are for the regulator cable guide bar and three are for the motor attachment (if the vehicle is
equipped with electric windows).
NOTE: IN THE NEXT STEP, BE CAREFUL NOT TO TWIST THE CABLES OF THE WINDOW
REGULATOR ASSEMBLY.
5. Position the new drum and cable window regulator in the door and attach the cable guide bar
with 5 screws (4 - P/N 6501682 and 1 - P/N 6100557) which is used at the up stop position. The
top screw should be left loose for now and tightened when making the final adjustment to the
up-stop in step 10.
6. A) For electric regulator equipped vehicles, attach the motor to the inner door panel using 3 nut &
washer assemblies (P/N 6100048).
B) For manual regulator equipped vehicles, attach the manual drive assembly to the inner door
panel with 2 screws (P/N 6501682).
7. Using the original hardware, attach the glass to the regulator.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Window Regulator: > 232993 > Jun > 93 > Window Regulator Inoperative > Page 6293
8. If the vehicle is electric regulator equipped, locate the wiring harness extension package (P/N
K4746909). Determine which insulator in the package needs to be installed to the door harness
end of the wiring harness extension (black for 1988 and prior, red for 1989 and 1990). Referring to
Figure 2 for proper wire to insulator orientation, assemble the appropriate insulator to the wiring
harness extension. If the red insulator is used, the wedge must be installed in the terminal end of
the insulator and xmas tree fastener must be inserted into the slot on the side of the red insulator.
9. Install the wiring harness extension (P/N K4746909). Use the xmas tree fasteners of the
insulators to secure the harness to the door, refer to Figure 3. At the forward attachment point, the
insulator must be installed so it is inside the door cavity. At mid-door attachment, install the
insulator so it is outside the door cavity. Bend the tab back into the door so the insulator becomes
flush to slightly underflush with the inner door panel.
10. Verify the proper operation of the window. Adjust as necessary. Tighten the upstop screw.
11. Reinstall the door trim.
POLICY: Information Only
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Window Regulator: > 232993 > Jun > 93 > Window Regulator Inoperative > Page 6294
TIME ALLOWANCE: Labor Operation No.
23-34-10-96 Power Window Regulator 1.0 Hrs.
23-34-10-97 Manual Window Regulator 0.9 Hrs.
FAILURE CODE: 27 - Damaged
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Manual Window Regulator Replacement
Window Regulator: Service and Repair Manual Window Regulator Replacement
*** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-29-93 DATED JUNE 4, 1993
Power Window Regulator Assembly
REMOVAL
1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair
2. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair
3. Drill out the five (5) rivets holding the power door regulator to the door.
4. Remove two (2) screws at the door sill.
5. Remove the manual window regulator by rotating it out of the door.
INSTALLATION
1. Install the manual window regulator by rotating it as it is installed.
2. Install the two (2) screws at the door sill.
Window Regulator Tightening Sequence
3. Install five (5) 1/4-20 X 1/2 screws in place of the rivets that were drilled out for removal. Using
the sequence shown, torque the screws to 90 lb-in (11 Nm).
4. Install the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair
5. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Manual Window Regulator Replacement > Page 6297
Window Regulator: Service and Repair Power Window Regulator Replacement
*** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-29-93 DATED JUNE 4, 1993
Power Window Regulator Assembly
REMOVAL
1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front
Door/Front Door Panel/Service and Repair
2. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair
3. Drill out the five (5) rivets holding the power door regulator to the door.
4. Remove two (2) screws at the door sill.
5. Remove the power window regulator by rotating it out of the door.
INSTALLATION
1. Install the power window regulator by rotating it as it is installed.
2. Install the two (2) screws at the door sill.
Window Regulator Tightening Sequence
3. Install five (5) 1/4-20 X 1/2 screws in place of the rivets that were drilled out for removal. Using
the sequence shown, torque the screws to 90 lb-in (11 Nm).
4. Install the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair
5. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Front Door Panel/Service and Repair
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical
Service Bulletins > Customer Interest: > 232692 > Oct > 92 > Windshield Washer Nozzle - Freezes Up
Check Valve: Customer Interest Windshield Washer Nozzle - Freezes Up
NO.: 23-26-92
GROUP: Body
DATE: Oct. 19, 1992
SUBJECT: Windshield Washer Nozzle Freeze Up
MODELS:
1989 - 1992 (AS) Caravan/Grand Caravan/Caravan C/V
Voyager/Grand Voyager/Town & Country
1989 - 1993 (AA)Spirit/Acclaim/Lebaron Sedan 1989 - 1993 (AC)Dynasty/New Yorker/New Yorker
Salon 1989 - 1993 (AG)Daytona 1989 - 1993 (AJ) Lebaron Coupe/Lebaron Convertible 1989 1993 (AP)Shadow/Shadow Convertible/Sundance 1990 - 1993 (AY)Imperial/New Yorker Fifth
Avenue
NOTE: THIS BULLETIN MAY BE APPLIED TO OLDER VEHICLES WITH WIPER ARM
MOUNTED NOZZLES.
SYMPTOM/CONDITION:
Inoperative windshield washer system when ambient temperatures are below freezing. One or all
nozzles may be affected and the frozen restriction can be anywhere between the washer fluid
reservoir and the nozzle(s).
PARTS REQUIRED:
1 Washer fluid check valve 4740043
REPAIR PROCEDURE:
This bulletin involves installing an in-line check valve in the windshield washer hose.
1. Pinch off the washer hose near the reservoir to prevent fluid from running out of the reservoir.
2. Cut a one inch section out of the hose two to three inches from the reservoir.
3. Locate the arrow molded on the check valve (P/N 4740043). Install the check valve in the hose
so the arrow points away from the reservoir.
4. Verify system operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 23-43-10-91 ......0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 232692 > Oct > 92 > Windshield Washer Nozzle - Freezes Up
Check Valve: All Technical Service Bulletins Windshield Washer Nozzle - Freezes Up
NO.: 23-26-92
GROUP: Body
DATE: Oct. 19, 1992
SUBJECT: Windshield Washer Nozzle Freeze Up
MODELS:
1989 - 1992 (AS) Caravan/Grand Caravan/Caravan C/V
Voyager/Grand Voyager/Town & Country
1989 - 1993 (AA)Spirit/Acclaim/Lebaron Sedan 1989 - 1993 (AC)Dynasty/New Yorker/New Yorker
Salon 1989 - 1993 (AG)Daytona 1989 - 1993 (AJ) Lebaron Coupe/Lebaron Convertible 1989 1993 (AP)Shadow/Shadow Convertible/Sundance 1990 - 1993 (AY)Imperial/New Yorker Fifth
Avenue
NOTE: THIS BULLETIN MAY BE APPLIED TO OLDER VEHICLES WITH WIPER ARM
MOUNTED NOZZLES.
SYMPTOM/CONDITION:
Inoperative windshield washer system when ambient temperatures are below freezing. One or all
nozzles may be affected and the frozen restriction can be anywhere between the washer fluid
reservoir and the nozzle(s).
PARTS REQUIRED:
1 Washer fluid check valve 4740043
REPAIR PROCEDURE:
This bulletin involves installing an in-line check valve in the windshield washer hose.
1. Pinch off the washer hose near the reservoir to prevent fluid from running out of the reservoir.
2. Cut a one inch section out of the hose two to three inches from the reservoir.
3. Locate the arrow molded on the check valve (P/N 4740043). Install the check valve in the hose
so the arrow points away from the reservoir.
4. Verify system operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 23-43-10-91 ......0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Check Valve: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear
or Streak Windshield
Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations
Wiper Control Module: Locations
I/P, Cowl & Steering Column Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
Engine Compartment Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Service and Repair
Windshield Washer Switch: Service and Repair
Fig. 2 Ignition lock removal. Models w/tilt column
FRONT
Standard Column
Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper
switch replacement procedure.
Tilt Column
1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES.
2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning
Switch, Replace."
3. Remove ignition key lamp.
4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock
cylinder release holes and push inward until spring loaded lock cylinder retainers release.
5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge
spring and pulling straight out. Use caution not to drop switch into steering column.
6. Remove three switch housing cover attaching screws, then the housing cover.
7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if
necessary.
8. Reverse procedure to install. Rearm airbag system.
REAR
1. Disconnect battery ground cable.
2. Remove switch plate bezel.
3. Remove four screws attaching switch plate to lower panel.
4. Pull switch assembly rearward, then disconnect switch electrical connectors.
5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
Wiper Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 6336
Wiper Switch: Testing and Inspection
Fig. 11 Two Speed Wiper Switch Continuity Chart
Fig. 12 Intermittent Wiper Switch Continuity Chart
1. Disconnect electrical connector to switch at body wiring harness connector. 2. Operate switch in
all positions, and check continuity between terminals with an ohmmeter. The first (clockwise)
position is the Off position.
Next is the slide for the Delay wipe, with counterclockwise rotation, reducing the delay. Low is the
next detent position. High is the full counterclockwise detent position. In any wiper mode, if the
knob is pushed in all the way, the washer circuit will be completed.
3. If continuity is not as specified in charts, replace switch.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 6337
Wiper Switch: Service and Repair
Fig. 2 Ignition lock removal. Models w/tilt column
FRONT
Standard Column
Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper
switch replacement procedure.
Tilt Column
1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES.
2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning
Switch, Replace."
3. Remove ignition key lamp.
4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock
cylinder release holes and push inward until spring loaded lock cylinder retainers release.
5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge
spring and pulling straight out. Use caution not to drop switch into steering column.
6. Remove three switch housing cover attaching screws, then the housing cover.
7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if
necessary.
8. Reverse procedure to install. Rearm airbag system.
REAR
1. Disconnect battery ground cable.
2. Remove switch plate bezel.
3. Remove four screws attaching switch plate to lower panel.
4. Pull switch assembly rearward, then disconnect switch electrical connectors.
5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Locations
Washer Fluid Level Switch: Locations
Engine Compartment Components.
LH Rear Corner Of Engine Compartment
Applicable to: 1989 4-153/2.5L & V6-181/3.0L
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Locations
Windshield Washer Pump: Locations
Rear Body Components
LH Rear Corner Of Cargo Compartment
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information >
Technical Service Bulletins > Customer Interest: > 232692 > Oct > 92 > Windshield Washer Nozzle - Freezes Up
Windshield Washer Spray Nozzle: Customer Interest Windshield Washer Nozzle - Freezes Up
NO.: 23-26-92
GROUP: Body
DATE: Oct. 19, 1992
SUBJECT: Windshield Washer Nozzle Freeze Up
MODELS:
1989 - 1992 (AS) Caravan/Grand Caravan/Caravan C/V
Voyager/Grand Voyager/Town & Country
1989 - 1993 (AA)Spirit/Acclaim/Lebaron Sedan 1989 - 1993 (AC)Dynasty/New Yorker/New Yorker
Salon 1989 - 1993 (AG)Daytona 1989 - 1993 (AJ) Lebaron Coupe/Lebaron Convertible 1989 1993 (AP)Shadow/Shadow Convertible/Sundance 1990 - 1993 (AY)Imperial/New Yorker Fifth
Avenue
NOTE: THIS BULLETIN MAY BE APPLIED TO OLDER VEHICLES WITH WIPER ARM
MOUNTED NOZZLES.
SYMPTOM/CONDITION:
Inoperative windshield washer system when ambient temperatures are below freezing. One or all
nozzles may be affected and the frozen restriction can be anywhere between the washer fluid
reservoir and the nozzle(s).
PARTS REQUIRED:
1 Washer fluid check valve 4740043
REPAIR PROCEDURE:
This bulletin involves installing an in-line check valve in the windshield washer hose.
1. Pinch off the washer hose near the reservoir to prevent fluid from running out of the reservoir.
2. Cut a one inch section out of the hose two to three inches from the reservoir.
3. Locate the arrow molded on the check valve (P/N 4740043). Install the check valve in the hose
so the arrow points away from the reservoir.
4. Verify system operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 23-43-10-91 ......0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 232692 > Oct > 92 > Windshield Washer Nozzle - Freezes
Up
Windshield Washer Spray Nozzle: All Technical Service Bulletins Windshield Washer Nozzle Freezes Up
NO.: 23-26-92
GROUP: Body
DATE: Oct. 19, 1992
SUBJECT: Windshield Washer Nozzle Freeze Up
MODELS:
1989 - 1992 (AS) Caravan/Grand Caravan/Caravan C/V
Voyager/Grand Voyager/Town & Country
1989 - 1993 (AA)Spirit/Acclaim/Lebaron Sedan 1989 - 1993 (AC)Dynasty/New Yorker/New Yorker
Salon 1989 - 1993 (AG)Daytona 1989 - 1993 (AJ) Lebaron Coupe/Lebaron Convertible 1989 1993 (AP)Shadow/Shadow Convertible/Sundance 1990 - 1993 (AY)Imperial/New Yorker Fifth
Avenue
NOTE: THIS BULLETIN MAY BE APPLIED TO OLDER VEHICLES WITH WIPER ARM
MOUNTED NOZZLES.
SYMPTOM/CONDITION:
Inoperative windshield washer system when ambient temperatures are below freezing. One or all
nozzles may be affected and the frozen restriction can be anywhere between the washer fluid
reservoir and the nozzle(s).
PARTS REQUIRED:
1 Washer fluid check valve 4740043
REPAIR PROCEDURE:
This bulletin involves installing an in-line check valve in the windshield washer hose.
1. Pinch off the washer hose near the reservoir to prevent fluid from running out of the reservoir.
2. Cut a one inch section out of the hose two to three inches from the reservoir.
3. Locate the arrow molded on the check valve (P/N 4740043). Install the check valve in the hose
so the arrow points away from the reservoir.
4. Verify system operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No. 23-43-10-91 ......0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Windshield Washer Spray Nozzle: > 23-014-06 > Mar > 06 >
Wipers/Washers - Wipers Smear or Streak Windshield
Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service
and Repair
Windshield Washer Switch: Service and Repair
Fig. 2 Ignition lock removal. Models w/tilt column
FRONT
Standard Column
Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper
switch replacement procedure.
Tilt Column
1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES.
2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning
Switch, Replace."
3. Remove ignition key lamp.
4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock
cylinder release holes and push inward until spring loaded lock cylinder retainers release.
5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge
spring and pulling straight out. Use caution not to drop switch into steering column.
6. Remove three switch housing cover attaching screws, then the housing cover.
7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if
necessary.
8. Reverse procedure to install. Rearm airbag system.
REAR
1. Disconnect battery ground cable.
2. Remove switch plate bezel.
3. Remove four screws attaching switch plate to lower panel.
4. Pull switch assembly rearward, then disconnect switch electrical connectors.
5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate.
6. Reverse procedure to install.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service
Bulletins > Customer Interest: > 231189 > May > 89 > Wiper Arm - Loose
Wiper Arm: Customer Interest Wiper Arm - Loose
Models
1989 AA, AC, AH, AP & AS Bodies
Subject
Wiper Arm Loose On Pivot Shaft
Index
BODY
Date
May 22, 1989
No.
23-11-89
(C23-04-9)
P-1976 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM AC - DYNASTY/NEW YORKER/LANDAU AH - LANCER/LeBARON GTS
(4-DOOR HATCHBACK) AP - SHADOW/SUNDANCE AS - CARAVAN/VOYAGER/CARAVAN C/V
SYMPTOM/CONDITION
Windshield wiper arm attachment to the pivot shaft may strip and loosen due to insufficient torque
or excessive loading on wiper arm.
Loose wiper arms which have not been otherwise damaged may be reused by removing and
reinstalling, using the following procedure. This will allow the arm to re-establish a tight fit on the
pivot shaft splines.
If the wiper arm is cracked or damaged, a new arm must be installed following this same
procedure.
Figure 1
REPAIR PROCEDURE
1. Lift the wiper arm and place a 1/8" (3.5 mm) pin (Allen wrench, nail, etc.) into the arm pin hole
(see Figure 1).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service
Bulletins > Customer Interest: > 231189 > May > 89 > Wiper Arm - Loose > Page 6378
Figure 2
2. Lift the head cover and remove the wiper arm attaching nut (see Figure 2).
3. Remove wiper arm from the pivot using a rocking motion.
4. Using a wire brush, clean the wiper pivot shaft splines thoroughly to remove any metal filings.
5. Cycle the windshield wiper motor to the park position and install wiper arm as follows:
- For AC, AH, AP and AA bodies position wiper arm so that blade tip is 3/4" from top of cowl
screen.
- For AS body, position wiper arms so that blade tips are located as follows:
Left: 5.0 mm (2.0") above windshield cowl top
Right: 2.5 mm (1.0") above windshield cowl top
6. Tighten the retaining nut to the torque value indicated below.
- For vehicles with a 10 mm pivot shaft nut (built prior to February, 1989) torque to 120 in.lbs (14
N-m).
- For vehicles with a 13 mm pivot shaft nut (built after February, 1989) torque to 175 in.lbs (20
N-m).
7. Run wiper motor to check for correct operation of wiper arms.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operations No.
23-43-60-90 . . . . . . . . . . . . . . . 0.2 Hrs.
FAILURE CODE: K4 - Loose
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 231189 > May > 89 > Wiper Arm - Loose
Wiper Arm: All Technical Service Bulletins Wiper Arm - Loose
Models
1989 AA, AC, AH, AP & AS Bodies
Subject
Wiper Arm Loose On Pivot Shaft
Index
BODY
Date
May 22, 1989
No.
23-11-89
(C23-04-9)
P-1976 BODY CODE LEGEND
AA - SPIRIT/ACCLAIM AC - DYNASTY/NEW YORKER/LANDAU AH - LANCER/LeBARON GTS
(4-DOOR HATCHBACK) AP - SHADOW/SUNDANCE AS - CARAVAN/VOYAGER/CARAVAN C/V
SYMPTOM/CONDITION
Windshield wiper arm attachment to the pivot shaft may strip and loosen due to insufficient torque
or excessive loading on wiper arm.
Loose wiper arms which have not been otherwise damaged may be reused by removing and
reinstalling, using the following procedure. This will allow the arm to re-establish a tight fit on the
pivot shaft splines.
If the wiper arm is cracked or damaged, a new arm must be installed following this same
procedure.
Figure 1
REPAIR PROCEDURE
1. Lift the wiper arm and place a 1/8" (3.5 mm) pin (Allen wrench, nail, etc.) into the arm pin hole
(see Figure 1).
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 231189 > May > 89 > Wiper Arm - Loose > Page 6384
Figure 2
2. Lift the head cover and remove the wiper arm attaching nut (see Figure 2).
3. Remove wiper arm from the pivot using a rocking motion.
4. Using a wire brush, clean the wiper pivot shaft splines thoroughly to remove any metal filings.
5. Cycle the windshield wiper motor to the park position and install wiper arm as follows:
- For AC, AH, AP and AA bodies position wiper arm so that blade tip is 3/4" from top of cowl
screen.
- For AS body, position wiper arms so that blade tips are located as follows:
Left: 5.0 mm (2.0") above windshield cowl top
Right: 2.5 mm (1.0") above windshield cowl top
6. Tighten the retaining nut to the torque value indicated below.
- For vehicles with a 10 mm pivot shaft nut (built prior to February, 1989) torque to 120 in.lbs (14
N-m).
- For vehicles with a 13 mm pivot shaft nut (built after February, 1989) torque to 175 in.lbs (20
N-m).
7. Run wiper motor to check for correct operation of wiper arms.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operations No.
23-43-60-90 . . . . . . . . . . . . . . . 0.2 Hrs.
FAILURE CODE: K4 - Loose
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiper Arm: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak
Windshield
Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak
Windshield
Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or
Streak Windshield
Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
Wiper Control Module: Locations
I/P, Cowl & Steering Column Components
Center Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations
Wiper Motor: Locations
Liftgate Components
Center Of Liftgate
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
Wiper Switch: Locations
Lower I/P Components
LH Side Of I/P
Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
6417
Wiper Switch: Testing and Inspection
Fig. 11 Two Speed Wiper Switch Continuity Chart
Fig. 12 Intermittent Wiper Switch Continuity Chart
1. Disconnect electrical connector to switch at body wiring harness connector. 2. Operate switch in
all positions, and check continuity between terminals with an ohmmeter. The first (clockwise)
position is the Off position.
Next is the slide for the Delay wipe, with counterclockwise rotation, reducing the delay. Low is the
next detent position. High is the full counterclockwise detent position. In any wiper mode, if the
knob is pushed in all the way, the washer circuit will be completed.
3. If continuity is not as specified in charts, replace switch.